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Preheating Steel Tubes Prior to BondingPreheating Steel Tubes Prior to Bonding

To heat steels tubes for a bonding application; the end product is a bushing for large trucks. Induction would replace an oven for this client. 

Heating a Copper Wire for Coating RemovalHeating a Copper Wire for Coating Removal

A custom-designed multiple turn helical coil was built to generate the required heating for this coating removal application.

Heating a Steel Pan to Evaporate WaterHeating a Steel Pan to Evaporate Water

A multiple turn pancake coil was designed to provide heat to the base of the steel pan. Initial tests were conducted to optimize the power delivered to the part and to understand the heating patterns

Brazing Steel Assemblies (hydraulics)Brazing Steel Assemblies (hydraulics)

A custom-designed single position multiple-turn oval split helical coil was built to generate the required heating for this brazing application.

Heating Stainless Steel Assemblies to Remove GlassHeating Stainless Steel Assemblies to Remove Glass

A custom-designed single position multiple-turn helical coil was built to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.

Brazing an Aluminum Tube AssemblyBrazing an Aluminum Tube Assembly

A custom-designed single position multiple-turn pancake coil was built to generate the required heating for this brazing application. Initial tests were conducted to optimize power delivery to the assembly

Heating Steel Assemblies for SealingHeating Steel Assemblies for Sealing

A single position multiple-turn pancake shaped coil was built to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.

Heating a Flanged Part Before WeldingHeating a Flanged Part Before Welding

A custom-designed single position multiple-turn oval coil was built to generate the required heating for the preheating application. Initially, a helical coil design was used which did heat the part faster, but the pattern wasn’t uniform.

Brazing a Carbide and Steel AssemblyBrazing a Carbide and Steel Assembly

A custom-designed single position multiple-turn helical coil was built to generate the required heating for this brazing application. Initial tests were conducted to optimize power delivery.

Brazing Copper Tubes for a Solar Industry ApplicationBrazing Copper Tubes for a Solar Industry Application

A custom-designed single position multiple-turn split-helical coil was built to generate the required heating for this brazing application.

Heating a Steel Susceptor for Glass CuttingHeating a Steel Susceptor for Glass Cutting

A custom-designed single position multiple-turn helical coil was built to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.

Brazing FishhooksBrazing Fishhooks

A custom designed single position multiple-turn helical coil was built to generate the required heating for the application.

Heating Non-Magnetic Steel TubingHeating Non-Magnetic Steel Tubing

To heat non-magnetic steel tubing for an application in the energy storage market.

Brazing Copper BussbarsBrazing Copper Bussbars

A custom-designed single position multiple-turn helical coil was built to generate the required heating for the application.

Heating Surgical Tools for Coating Burn OffHeating Surgical Tools for Coating Burn Off

To heat surgical tools to burn-off the nylon coating; the client had been using a torch for this application. Within seconds of the power being turned on, the coating on the tool began to smoke and soon started to bubble.

Heating Steel Cutting Tools for Carbide RemovalHeating Steel Cutting Tools for Carbide Removal

Using induction to heat magnetic steel cutting tools for removal of carbide cutting tips. Induction efficiently and precisely heats the client's part in a controlled manner delivering only the required heat.

Brazing a Copper Tube & Brass FittingBrazing a Copper Tube & Brass Fitting

A custom-designed single position multiple-turn U-shape coil was built to generate the required heating for this brazing application.

Heating Steel Coated Copper WireHeating Steel Coated Copper Wire

In static tests, it was observed that it took 2.5 seconds to heat an 11” (279 mm) length of sample wire to target temperature.

Brazing Copper and Brass ValvesBrazing Copper and Brass Valves

To braze various copper and brass assemblies for a valve manufacturer; they are looking to replace their torch heating process with induction

Brazing Steel Fittings & Tubes (Hydraulics)Brazing Steel Fittings & Tubes (Hydraulics)

Braze steel fittings and tubes in an atmosphere to make hydraulic fittings within a targeted heating time of under 150 seconds.

Heating Steel Shafts for Forming (Medical Tools)Heating Steel Shafts for Forming (Medical Tools)

A custom-designed single position multiple-turn helical coil was built to generate the required heating for this application.

Heating Graphite DiscsHeating Graphite Discs

A custom-designed single position multiple-turn pancake coil was built to generate the required heating for this application.

Brazing Both Ends of a Steel AssemblyBrazing Both Ends of a Steel Assembly

The client wanted to braze both ends of the part concurrently within their time requirements. Induction met the client’s time requirements and is often faster than other heating methods. With induction there is no open flame and with induction’s instant on/off capabilities, it introduces less heat into the work environment.

Heating Steel Pipe for a Casting SystemHeating Steel Pipe for a Casting System

The client wants to replace their resistive steel pipe heating process; it takes 15 minutes to reach the desired temperature.

Brazing Copper and Brass Fittings (Flange)Brazing Copper and Brass Fittings (Flange)

How to braze copper tubes and a steel plate for a brazing application; while this is a new process for the client, they also tested the process with a torch

Steel Nozzle Assembly (Aerospace)Steel Nozzle Assembly (Aerospace)

Where you can struggle with repeatability with an oven and torch, induction brazing is a more repeatable process. With induction heating, there is no open flame and the benefit of instant on/off capabilities. This introduces less heat into the work environment.

Preheating Parts for WeldingPreheating Parts for Welding

Induction dramatically reduced the heating time they saw with torch heating as it dropped from 20 minutes to 3 minutes

Brazing Brass and Copper NozzlesBrazing Brass and Copper Nozzles

To braze copper and brass samples for an application in the aerospace industry, induction heating was used in place of a previously used torch. Induction brazing allows more consistent, higher quality parts.du

Heating Steel Knives; Food ProcessingHeating Steel Knives; Food Processing

To rapidly heat steel knives on the line of a food processing facility, improving efficiency; the client had been using a different heating method.

Brazing a Steel Part for the Aerospace IndustryBrazing a Steel Part for the Aerospace Industry

A custom-designed multiple-turn helical coil was built to generate the required heating for a steel cable for the aerospace industry. Induction brazing was used to heat a steel part for a brazing application.

Drying Steel Rings with Induction HeatingDrying Steel Rings with Induction Heating

To heat streel rings for a drying application; the client was using hot air but it wasn’t completely drying the rings

Brazing, De-brazing Carbide, Steel PlatesBrazing, De-brazing Carbide, Steel Plates

A custom-designed special multiple-turn helical coil was built to generate the required heating to heat a carbide and steel plate assembly for a brazing and de-brazing application in the oil and gas industry.

Preheating Rod Assemblies for WeldingPreheating Rod Assemblies for Welding

The client had been using torches for preheating. However, due to process improvements thanks to new automation in their facility, torch heating became too slow. This resulted in a backlog that kept them from maximizing their throughput.

Brazing Brass Assembly; Sink ManufacturerBrazing Brass Assembly; Sink Manufacturer

To heat brass assemblies for a brazing application, the client, who manufactures sink products had been using a torch. Induction heating heated the assembly to temperature and better met the client’s time requirements.

Induction Preheating Steel Laminate PartsInduction Preheating Steel Laminate Parts

The c-lams are inserts for an automotive industry application. In production the robotic pick-and-place will occur for plastic overmolding after heating by induction.

Brazing a Copper Tube and Steel PlateBrazing a Copper Tube and Steel Plate

In order to braze copper, a custom-designed single position multiple-turn helical coil was built to generate the required heating for the tube-to-plate brazing application. Initial tests were conducted to optimize the power delivered to the part. Repeatability was a top priority for this client.

Heating Busbars for Coating ReleaseHeating Busbars for Coating Release

Induction’s precision heating enables the part to heat to the exact targeted temperature, which prevented melting of the tin-coated copper part

Heating Automotive Battery Cables for Adhesive MeltingHeating Automotive Battery Cables for Adhesive Melting

Temperature indicating paint was applied to the parts, and it took 10 seconds to heat the various styles of the part to the targeted temperature. This testing achieved the client's time and quality objectives.

Brazing a Nickel Pin and a Nickel WireBrazing a Nickel Pin and a Nickel Wire

A client had been using flame heating to braze a nickel pin and a braided nickel wire. The end-product is a heater assembly. Using induction improved joint quality compared to using flame heating.

Heating Lighting Tubes for Getter FiringHeating Lighting Tubes for Getter Firing

The getter firing application was complete within just 10 seconds. Induction delivers the same result time after time, making it ideal for their high-volume manufacturing process

Brazing a Carbide Tip and Magnetic Steel TubeBrazing a Carbide Tip and Magnetic Steel Tube

To braze carbide inserts into magnetic steel tubes, an inconsistent torch process was replaced with induction brazing equipment. In this application, quality rather than speed was the top priority.b

Heating Wires and Strips for Coating RemovalHeating Wires and Strips for Coating Removal

The polymer coating on the aluminum strip behaved differently when heated. Visually, the coating turned brown and bubbly when the aluminum strip was heated

Brazing a Steel and Carbide AssemblyBrazing a Steel and Carbide Assembly

To braze a steel and carbide assembly to create a mining bit for the oil and gas industry, this client replaced their torch process with the repeatable and flameless induction brazing technique.

Braze a Copper Tube and Brass Fitting (fuel containment)Braze a Copper Tube and Brass Fitting (fuel containment)

How to braze copper using a custom-designed single position multi-turn helical coil built to generate the required heating for the copper brazing application.

Heating an Aluminum Tube for BendingHeating an Aluminum Tube for Bending

Induction does not present an open flame into the work environment like a torch, resulting in a safer working environment

Brazing a Copper Strip AssemblyBrazing a Copper Strip Assembly

The client requested a system that would meet their time objectives which the EKOHEAT easily did, boosting the client's throughput.

Heat a Fixture for a Wire Heating ApplicationHeat a Fixture for a Wire Heating Application

Heat a non-magnetic metal alloy shape-setting fixture for a Nitinol wire heating/shaping application.

Induction brazing a Steel Tube with External Wire BraidInduction brazing a Steel Tube with External Wire Braid

The coil selected is not only capable of induction heating the steel 7/8/22 mm tube, but also a smaller tube that the client needs to heat.

Heating a Tube Prior to SwagingHeating a Tube Prior to Swaging

With the process designed by Ambrell's applications engineers, the tubing heated to temperature within five seconds. This result met the client's objective

Brazing, De-Brazing Diamond Carbide InsertsBrazing, De-Brazing Diamond Carbide Inserts

Heat steel cutting bits with diamond-carbide inserts for brazing and de-brazing; the end products are cutting tools

Preheating a titanium alloy wire prior to weldingPreheating a titanium alloy wire prior to welding

With an EKOHEAT 10 kW power supply, the titanium alloy wire can be heated to 2732 °F (1500 °C) in three seconds. This testing configuration simulates using three EASYHEAT 10 kW power supplies in series.

Brazing a steel and carbide dental assemblyBrazing a steel and carbide dental assembly

This configuratoin achieved the client's objective. The channel coil - specially designed by THE LAB at Ambrell- was critical to the application's success.

Brazing a brass tube and flange; torch replacementBrazing a brass tube and flange; torch replacement

Application engineers determined placing a turn that is targeted to the tube inside the part would optimize heating for this application. This heats the tube while the flange is being heated enabling both parts to achieve the required temperature concurrently.

Brazing a magnetic steel cutting tool with inductionBrazing a magnetic steel cutting tool with induction

Induction heating rapidly heats the steel parts to the required temperature, especially with the EKOHEAT's Auto Tap feature. The Ambrell Applications Lab used their expertise to create the right solution for the system and the system hardware.

Heating a cutting knife, improving cutHeating a cutting knife, improving cut

In this example, induction heating provides consistent, repeatable results, a safe, reliable source of heat, measurable & stable results and less production scrap

Preheating a magnetic steel diePreheating a magnetic steel die

The induction process required 10 minutes to heat to the required temperature; the client's resistance heater took more than ten minutes. Also there will no longer be a need to open the chamber to remove the heater.

Brazing a steel and copper strip to carbideBrazing a steel and copper strip to carbide

Induction heating of the steel took less than 30 seconds, is highly repeatable and there is no open flame, clear benefits over flame heating. it a safer method of heating than torch heating

Heating aluminum wire to create screensHeating aluminum wire to create screens

Induction will double production due to more rapid heating than infrared lamps can offer; with induction 100 feet per minute can be run instead of 50 feet per minute with infrared

Induction brazing a rectangular steel partInduction brazing a rectangular steel part

Induction heating of the steel took 30 seconds (or less), which can't be matched when using a torch. This client was using an old induction system from another vendor, and the Ambrell system provided considerably faster heating

Heating rods for thread rolling to create fastenersHeating rods for thread rolling to create fasteners

This is part of an automated line. The system was sized and the coil was designed to ensure 45 parts per minute can be heated to the temperature required for hot forming.

How to braze a copper tubeHow to braze a copper tube

The client had been using a torch, which took 50 seconds instead of 30; induction brazing the copper increased repeatability and in turn boosted part quality. Also, there is no open flame which makes it a safer method of heating than torch heating

Induction heating stainless steel inserts for an insertion applicationInduction heating stainless steel inserts for an insertion application

Induction heating offers dramatically faster heating compared to ultrasonics which means dramatically increased production rates. Induction is highly repeatable and easy-to-integrate into manufacturing processes.

Copper block & carbide; contact assemblyCopper block & carbide; contact assembly

Induction completed the carbide brazing process more rapidly than an oven, delivering heat exactly where it's needed, operating instant on/instant off

Hot forming a steel pipe with inductionHot forming a steel pipe with induction

A 2.5 inch steel pipe is heated by induction to the targeted temperature quickly with induction's repeatable process. EKOHEAT is easy to integrate into manufacturing processes and targets only the portion of the tube that requires bending while not heating the remainder of the tube.

Induction heating steel coupons and carbide cutters for brazing and de-brazingInduction heating steel coupons and carbide cutters for brazing and de-brazing

The first coupon that was heated had a 16 mm (0.63) diameter cutter, so removal of the cutter was the objective. The part was coated in black flux and inserted into the coil...

Brazing aluminum adaptors to the end of aluminum tubesBrazing aluminum adaptors to the end of aluminum tubes

To increase production, a multi-position coil was recommended so multiple parts could be heated while maintaining a cycle time of 55 seconds, delivering consistent joint quality, which a torch often doesn't deliver.

Induction heating a steel grenade for a disposing applicationInduction heating a steel grenade for a disposing application

The grenade was then placed inside the coil and power was turned on. After just two seconds the painted indicated, meaning the part achieved 800 °F (427 °C).

Brazing a nickel sleeve to a copper mastBrazing a nickel sleeve to a copper mast

To heat a nickel sleeve and a copper mast for a brazing application to create a pitot tube for the aerospace industry

Tempering an audio speaker screenTempering an audio speaker screen

The speaker screen was placed over the induction coil and the power was turned on. The screen heated to the desired temperature within just one second

Brazing a brass screw cap and a steel tubeBrazing a brass screw cap and a steel tube

Induction heating enables brazing the cap and tube to be completed at a rate of 15 seconds per part while delivering consistent joint quality in a safer environment which a torch often can't offer...

Brazing a stainless steel fitting to a stainless steel capillary tubeBrazing a stainless steel fitting to a stainless steel capillary tube

Induction enables consistent joint quality in about 35 seconds, which a torch often doesn't deliver; in this case this is the primary reason for switching to induction

Heating an aluminum-backed circuit board to reflow solderHeating an aluminum-backed circuit board to reflow solder

Given the significantly faster heating time, induction improves throughput in this process and is a more efficient heating method than hot plate heating

Heating a Kovar tube for a glass sealing applicationHeating a Kovar tube for a glass sealing application

The client was using a torch, and operator error was slowing the heating. The repeatability of induction enables improved throughput while in this process it is a more efficient heating method than torch heating, also reducing scrap

Brazing a steel coupler and a steel wireBrazing a steel coupler and a steel wire

Induction heating enabled the brazing process to be completed within 30 seconds. The client was using a torch, and induction offers superior repeatability with no open flame and delivering heat only where it's required...

Heating a chromel grid for an oxidization applicationHeating a chromel grid for an oxidization application

Induction delivers a dramatic reduction in heating time, enabling a significant increase in production while providing a more energy-efficient heating method than furnace heating

Induction Pre-heating a steel transaxle tube for a welding applicationInduction Pre-heating a steel transaxle tube for a welding application

Induction heating achieves an identical result consistently, and is a more efficient heating method, each of which are advantage over torch heating

Brazing brass tube and fitting assembliesBrazing brass tube and fitting assemblies

The brass tubes and fittings heated to required temperature far more quickly than with customer's torch method, resulting in improved part quality and introducing less heat into the production environment...

Pre-heating a steel plate and a carriage roller shaft with induction for a welding applicationPre-heating a steel plate and a carriage roller shaft with induction for a welding application

Induction heating achieves the client's targeted speed/production rate and opens up the possibility of preheating while welding

Brazing carbide tips to a steel cutterBrazing carbide tips to a steel cutter

The cutter was held in a vice and the coil was presented to heat the assembly. A ceramic rod was used to press the carbide tip onto steel cutter during brazing.

Heating fluid passing through an alumina tubeHeating fluid passing through an alumina tube

To heat an alumina tube to heat magnetic particles in order to heat fluid passing through the tube for an oil industry application

Brazing a copper tube assemblyBrazing a copper tube assembly

The proposed system is capable of heating a wide variety of tube assemblies, is light enough to be used on a cart and is able to meet the client's time/productivity objectives

Heating the joint area of two lead plates for a butt welding applicationHeating the joint area of two lead plates for a butt welding application

The client was using a torch, which took five minutes; induction takes just one minute, which means an improved production rate and, unlike a torch, induction heating is precise and repeatable...

Brazing a brass tube assembly (valve manufacturing)Brazing a brass tube assembly (valve manufacturing)

With the recommended coil configuration, the cycle time turned out to be 25% less than what the client was targeting, resulting in increased production efficiency; a good braze joint was formed, and induction's consistency and repeatability proved valuable

Induction heating cylinder liners for insertion into aluminum engine blocksInduction heating cylinder liners for insertion into aluminum engine blocks

Temperature indicating paint was applied to the steel part for testing purposes. The part was then placed into the induction heating coil and the power was turned on. In just under 30 seconds, the part achieved temperature.

How to braze three copper tubes to create a four-way valveHow to braze three copper tubes to create a four-way valve

Due to the use of a higher power system, speed expectations were exceeded and improved over the client's previous method, which was torch heating. A good copper braze joint was formed, and induction's consistency and repeatability proved valuable. Induction brazing doesn't employ an open flame, which results in a safer work environment

Heating stainless steel finned partsHeating stainless steel finned parts

Induction is a targeted, precise heating method with instant on/off, saving users energy and it is a flameless heating method, so it provides employees with a cooler, lower-risk working environment...

Brazing copper tubes to a brass manifold blockBrazing copper tubes to a brass manifold block

The proposed process met the client's time objective, and is faster than oven heating.

Heating a coated copper wire for a stripping applicationHeating a coated copper wire for a stripping application

The top 1 (25 mm) portion of the plastic coated wire was placed inside the helical coil and heating began. The top turn rapidly started to heat and the plastic melted after about 10 seconds of heating...

Brazing copper and brass valve assemblies (HVAC)Brazing copper and brass valve assemblies (HVAC)

The copper tube (1/8/3.2mm) is inserted into the flared copper tube (1/4/6.4mm). Two braze rings are placed on the copper tubes and the power is applied....

Heating a copper end cap to temperature to melt waxHeating a copper end cap to temperature to melt wax

To heat a copper end cap to temperature for a wax reflow application; the end product is a temperature stat and the client is looking to cut their heating time in half...

Brazing steel drill bits (aerospace)Brazing steel drill bits (aerospace)

The client wanted to heat three parts concurrently, and this process allowed up to five parts to be heated concurrently...

Preheating copper barsPreheating copper bars

To preheat two copper bars to temperature within 30 seconds; the client is looking to replace a competitor's 5kW induction heating system that is delivering unsatisfactory results

Brazing steel flange and shaft assemblies (aerospace and automotive applications)Brazing steel flange and shaft assemblies (aerospace and automotive applications)

Induction brazing is a repeatable process that isn't as labor intensive as a flame often is. The process can heat the assembly rapidly and more energy-efficiently than a torch without the safety risks that come with an open flame

Brazing two fittings and a helical tube to create a mountBrazing two fittings and a helical tube to create a mount

The client had been using a torch, and was dealing with inconsistent results that impacted part quality. Induction heats the assembly more quickly than the torch..

Heat steel plates of various thicknesses with induction on the same lineHeat steel plates of various thicknesses with induction on the same line

This in-line system enables the client to heat plates with significantly different thicknesses, while the feed-rate varies considerably based on the thickness of the part. Induction is the fastest method of heating steel plates to the required temperature

Brazing tubes and fittings for an air conditioning unit for the off-road marketBrazing tubes and fittings for an air conditioning unit for the off-road market

Clients were using an oven, and because the whole part was being heated and essentially annealed, it created problems with the part. Induction only heats the braze area, and resolves that issue...

Preheating a copper rod and connector [epoxy curing]Preheating a copper rod and connector [epoxy curing]

Induction heated the part to temperature quickly in a far more efficient method than an oven, heating only the parts of the rod that required heating

Brazing a steel and brass immersion heating elementBrazing a steel and brass immersion heating element

Induction results in faster heating than a torch with faster, multipart heating to increase output...

Heating a titanium bracelet; create the desired finishHeating a titanium bracelet; create the desired finish

Within 35 seconds the center band of the bracelet turned black. The client had been using a torch, but looked to induction due to speed, safety and repeatability...

Brazing an aluminum assembly for a bicycle manufacturing applicationBrazing an aluminum assembly for a bicycle manufacturing application

For this aluminum bicycle tube brazing application, induction heating delivers more repeatable and consistent results, while cutting client's heating time in half when compared to using a torch...

Preheating a titanium billet to temperature prior to rollingPreheating a titanium billet to temperature prior to rolling

Induction uniformly heats the large billet and the client's longer 15 foot billets quickly to 1800C.

Brazing a magnetic steel tube and steel mating assemblyBrazing a magnetic steel tube and steel mating assembly

Heating a 0.437 (11.1) in(mm) outside diameter magnetic steel tube and steel mating assembly to temperature for a brazing application to create an oil tube for the railroad industry...

Heating a nanoparticle solution to 40 °CHeating a nanoparticle solution to 40 °C

Heat a nanoparticle solution to get it to increase at least 40 °C for medical research/laboratory testing

Brazing an aluminum manifold [air conditioning]Brazing an aluminum manifold [air conditioning]

Precise, repeatable heating: The client wanted more precise and repeatable heating than a torch could deliver, which induction was able to achieve..

Stress relieving flat blanks of carbon steel to reduce wheel hardnessStress relieving flat blanks of carbon steel to reduce wheel hardness

Induction rapidly heats the carbon steel to temperature, enabling a rate of 30 feet per minute, not only saving production time, but saving energy costs. With a modest footprint, induction is easily implemented into production processes such as this one...

Brazing a steel tube and fitting to create an automotive valveBrazing a steel tube and fitting to create an automotive valve

Customer's client was unhappy with the results from MIG welding, which drove them to look at induction as an alternative process. Induction heating proved to be a fast, repeatable heating method for the application...

Heating an Inconel tube (incineration)Heating an Inconel tube (incineration)

Induction offers uniform heating, which flame does not offer, is more efficient than flame and can rapidly melt the materials

Brazing a carbide ball to a spring to create a part that controls the armature position in a motorBrazing a carbide ball to a spring to create a part that controls the armature position in a motor

To heat a tungsten carbide ball and steel rod that acts as a spring to 1300 °F (704 °C) within five seconds for a brazing application to create a part that governs the armature position in a motor...

Induction preheating a turbine blade (welding)Induction preheating a turbine blade (welding)

The end result is a preheating process that allows the part to move quickly to the welding step while meeting all quality requirements

Brazing a steel rod and sensor housing assemblyBrazing a steel rod and sensor housing assembly

To heat a steel rod and housing to 1400 °F (760 °C) within 30 seconds for a brazing application to create an assembly for a sensor...

Heating a steel ball on a pin by induction for an insertion applicationHeating a steel ball on a pin by induction for an insertion application

While the project is new, the customer wanted the steel part to be heated to temperature within four seconds, and that was easily achieved and exceeded with the EASYHEAT power supply

Heat a steel block with a cutout for carbide for a brazing applicationHeat a steel block with a cutout for carbide for a brazing application

Induction delivers improved quality and repeatability; client was using a torch and induction offered more precise, repeatable heating. In addition, this allowed the client to achieve the targeted heating time of 60 seconds, faster than what the torch could deliver...

Induction preheating steel rods for a welding applicationInduction preheating steel rods for a welding application

Induction heating does a superior job penetrating the pin when compared to a torch, which is critical to preheating for welding and enables fast heating which can boost production compared to torch heating

Brazing a copper elbow tube assemblyBrazing a copper elbow tube assembly

In this copper brazing process, induction offers more precise, repeatable heating than current flame process...

Induction preheating a steel automotive transaxle (welding)Induction preheating a steel automotive transaxle (welding)

The steel axle was painted with temperature indicating paint and a thermocouple was attached to the part.

Brazing copper tubing and brass fittings for aerospace partsBrazing copper tubing and brass fittings for aerospace parts

Induction heating achieves superior process repeatability when compared to a brazing torch and a more predictable aerospace parts which enhances quality..

Heat a block of Haynes nickel alloy to test the crack growth rateHeat a block of Haynes nickel alloy to test the crack growth rate

Testing was conducted to optimize the power delivered to the part. The coil was designed to minimize the voltage potential over the length of the part.

Brazing a steel tube and fitting assemblyBrazing a steel tube and fitting assembly

Induction heating is used to braze a steel connector onto a steel tube to create a hydraulic component. ...

Induction preheating a steel plate for forgingInduction preheating a steel plate for forging

The induction heating process achieved a production rate of 100 steel parts per hour, while a gas furnace produced 83 parts per hour; the process is repeatable and can be integrated into a production process

Brazing stainless steel medical tool parts into a couplingBrazing stainless steel medical tool parts into a coupling

Induction heating is used to achieve client's goal to braze both stainless steel parts as quickly as possible with maximum repeatability...

Brazing steel tube fittingsBrazing steel tube fittings

A tube assembly is heated to the desired braze temperature in 20-25 seconds, which achieves the client's targeted cycle time of less than 30 seconds...

Brazing a magnetic steel rotor assemblyBrazing a magnetic steel rotor assembly

Induction is proposed to replace a hand-operated flame process requiring operator training and expertise. Induction heating delivers a precise, repeatable and reliable process. Improved joint quality is coupled with simplified operation...

Induction Heating Tool-Steel Circular Dies to 400C in 10 minutesInduction Heating Tool-Steel Circular Dies to 400C in 10 minutes

Induction heating delivers heat directly into the steel part, saving energy and time, can be easily integrated with a press, presents a greatly reduced footprint compared with oven, batch, carts

Brazing carbide insert to steel pipe gripper chuckBrazing carbide insert to steel pipe gripper chuck

Induction heating is proposed to braze carbide inserts into steel blocks in the assembly of pipe gripper chuck. To replace a hand/flame process, delivering significant reduction in per-part cycles...

Hardening steel pipe segments (sleeves)Hardening steel pipe segments (sleeves)

Disappointed with low quality levels in a previously outsourced process, the customer uses induction to bring the heat treatment and the control of the end-product quality in-house.

Brazing a copper pipe assembly seamBrazing a copper pipe assembly seam

The customer is seam brazing copper pipes together. They will reduce the brazing of the seam down to 15-30 seconds.This customer is currently using a torch, but is not getting uniform quality

Heating a steel wire for temperingHeating a steel wire for tempering

Induction heating delivers heat directly into the wire, saving energy and time, easy integration into production line, improving throughput, precise control of heat and even distribution of heat within the wire

Brazing a pressure switch base assemblyBrazing a pressure switch base assembly

Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating precise and controllable heat

Preheating aluminum flangesPreheating aluminum flanges

Induction heating delivers higher quality end product vs. using an open flame convection furnace. Ovens are sensitive to ambient temperature and humidity variations and tend to produce uneven results

Brazing brass and steel for valves and end plugsBrazing brass and steel for valves and end plugs

The customer is currently using a torch to complete the braze joints. They wish to improve repeatability for a better process.

Desoldering Customer Assemblies with Induction HeatingDesoldering Customer Assemblies with Induction Heating

To heat customer assemblies for a desoldering application. The client had been outsourcing this task, but wanted to see if it would be viable to bring the process in house.

Heating a 4 Tubular Carbon Susceptor to 5400 °F (3000 °C)Heating a 4 Tubular Carbon Susceptor to 5400 °F (3000 °C)

A tubular carbon susceptor is held within an atmospherecontrolled quartz chamber. Induction is used to heat the susceptor

Brazing temperature sensor assembliesBrazing temperature sensor assemblies

A five-turn two-position helical coil is used for this brazing application. Each coil acts individually and the coils are not designed to heat simultaneously...

Soldering Brass and Copper ComponentsSoldering Brass and Copper Components

A solder wire preform was placed on the part to allow for repeatable placement of solder in every joint. Four top or four bottom joints will be heated at one time within 2-3 minutes for the soldering application.

Pre-heating aluminum wheels prior to spray paintingPre-heating aluminum wheels prior to spray painting

This spray painting application requires pre-heating the material. Additionally, there is a requirement that the material must not cool below a certain target temperature prior to the spray.

Heating a Copper Assembly for SolderingHeating a Copper Assembly for Soldering

To heat a glass feed-through inside a copper block for a soldering application, one side at a time. This was a new application/process for the client.

Heat an Inconel tube for a swaging applicationHeat an Inconel tube for a swaging application

A need to increase volume and quality of parts production led to the choice of an induction process over flame. Handling is minimized and continuity is assured with the precision delivery of heating only where required.

Brazing Copper Tubes to a Braided Stainless Steel HoseBrazing Copper Tubes to a Braided Stainless Steel Hose

Customer is currently using flame and a highly paid operator to complete this application. With an induction system, the customer can save approximately $20,000/year in operator cost alone, not factoring in any energy savings.

Soldering Ferrule and Module AssemblySoldering Ferrule and Module Assembly

To heat ferrule and module assemblies for a soldering application in the fiber optics industry.

Heating iron oxide (Fe3O4) nanoparticles in an aqueous solution for researchHeating iron oxide (Fe3O4) nanoparticles in an aqueous solution for research

An eight turn helical coil is used to heat the vials. 0.0625 thick insulation is wrapped around the vial and the vial is placed in the coil. The optical temperature probe is inserted into the vial with the base of the probe located in the middle of the coil turns.

Brazing two aluminum pipes to an aluminum evaporator coreBrazing two aluminum pipes to an aluminum evaporator core

The customer is replacing a flame process which can burn away the thin flange at the joint area and create scrap parts. By switching to induction for this application the customer is decreasing their scrap parts and also increasing their quality and production rate...

Soldering Co-axial Wire to a Metal FrameSoldering Co-axial Wire to a Metal Frame

Given the small size of the part and the assembly's geometry, a graphite cylinder was required as a susceptor.

Heating a pin assembly to cut holes in a rubberized materialHeating a pin assembly to cut holes in a rubberized material

Induction heating provides precise and consistent application of heat, consistent and repeatable results, hands-free heating that involves no operator skill for manufacturing

Brazing brass bellow assemblies for pneumatic regulatorsBrazing brass bellow assemblies for pneumatic regulators

Customer is replacing flame with induction to braze/solder these parts. While they are not looking to increase their production, they are looking for a repeatable and reliable process...

Heating a Kovar Ferrule for Glass SolderingHeating a Kovar Ferrule for Glass Soldering

The solder formed a relatively uniform domed seal around the fiber despite the asymmetry of the open C coil. It took under 10 seconds to heat the part to soldering temperature

Preheating a molybdenum anode for stress reliefPreheating a molybdenum anode for stress relief

A four turn helical pancake coil is used to heat the anode. The area on the anode to be preheated is the weld between the tube and flange.

Brazing a stainless steel shaft to a carbide for a digger used in miningBrazing a stainless steel shaft to a carbide for a digger used in mining

A three turn helical coil is used to braze the carbide to the shaft. The steel shaft is fluxed and the braze shim placed on top. The carbide tip is fluxed and placed on top of the shim, lining up the countersunk hole in the carbide. The hole is not fluxed because the flux outgases and causes the carbide to build up pressure and attempt to repel from the shaft...

Soldering Four Fusible Copper StripsSoldering Four Fusible Copper Strips

Soldering with Induction takes under 10 seconds to heat four copper strips concurrently, resulting in a boost in throughput for the client. Induction is a highly repeatable process that heats just the area of the copper strip that requires it

Heating a steel chain for temperingHeating a steel chain for tempering

A twenty turn helical coil is used to heat the chain. The chain is fed through the coil at a rate of 1 meter per minute to reach the desired 1760 °F (960 °C) for the tempering process.

Brazing a small gas delivery assembly used to manufacture needlesBrazing a small gas delivery assembly used to manufacture needles

This is a new part for the customer and they are developing the manufacturing process for it. The customer is interested in using induction heat for their process because they are looking for finished parts which are clean and not contaminated by any flux material. By using induction to braze the part and by doing the braze under a hydrogen atmosphere, the customer can produce brazed parts with no oxidation...

Soldering a pair of magnetic steel pinsSoldering a pair of magnetic steel pins

Soldering with induction required under 10 seconds and is a highly repeatable process; the customer can expect the same result every time with only the portion of the part requiring heating being heated.

Heating top of aluminum oxygen tank for end formingHeating top of aluminum oxygen tank for end forming

Through heating the top 2 (50.8mm) of aluminum oxygen tank to form a rounded end with a hole for oxygen valve

Brazing copper and steel tube combinations for refrigeration and air conditioningBrazing copper and steel tube combinations for refrigeration and air conditioning

Customer is currently using flame brazing in a large facility for this application and will gain safety benefits with induction such as no hazardous fumes or open flames...

Soldering a rivet onto a steel tank cap with induction heatingSoldering a rivet onto a steel tank cap with induction heating

Soldering with induction proved faster than the client's previous heating torch process. It is also is a repeatable heating process, so the client gets superior results and is more energy efficient than torch heating.

Preheating steel bar stock to forge a hot formed u-boltPreheating steel bar stock to forge a hot formed u-bolt

A fifteen turn helical coil with ceramic insert is used to preheat the 15 (381 mm) section of steel bar stock.

Brazing a spray bar assembly used for powder coatingBrazing a spray bar assembly used for powder coating

Customer is currently outsourcing this application. By bringing in-house they will save on inventory build-up, transportation cost, time-to-customer and money. Customer found Ambrell on the web and liked the idea that Ambrell's application lab can prove capability before purchasing.....

Heating a steel tie down assembly to loosen steel pin for rotationHeating a steel tie down assembly to loosen steel pin for rotation

Induction heating provides precise and accurate placement of heat without affecting surrounding areas, much faster process time, from hours to minutes, repeatable and consistent results and even distribution of heating

Brazing vertical copper bars to a copper slip ring for refurbishing large motor assembliesBrazing vertical copper bars to a copper slip ring for refurbishing large motor assemblies

A three-turn helical coil is used to heat the slip ring. Power is applied for 25 minutes to bring the ring up to brazing temperature. The slip ring is then held at temperature as the self locating 52 vertical bars are brazed into place...

Soldering copper tabs for stringing, tabbing solar panelsSoldering copper tabs for stringing, tabbing solar panels

Induction's precision soldering ensures repeatable results and less damage to surrounding substrates while demonstrating reduced heat loss and lower energy usage...

Heating a carbon steel plate with a tin coating for flow-meltingHeating a carbon steel plate with a tin coating for flow-melting

A nine turn Dog Bone style coil is used for the flow-melting process. The tin coated carbon steel plate is placed in the coil for 1.34 seconds to uniformly reflow the tin coating.

Brazing copper cable and block assembly for generator repairsBrazing copper cable and block assembly for generator repairs

A three-turn helical combination channel coil is used to heat the assembly. The assembly is placed in the coil with a thin ceramic paper placed between the coil and copper assembly...

Soldering electrical wire to a copper groundingSoldering electrical wire to a copper grounding

For this grounding lug soldering application, induction delivers consistent result is achieved each time and does not present a flame, so it helps create a safer, cooler working environment than other methods

Preheat steel for reformingPreheat steel for reforming

Induction heating provides controllable heat pattern, ease of on site location use, safe, no open flames and even distribution of heating

Brazing aluminum electrical lug assemblyBrazing aluminum electrical lug assembly

A five turn helical coil is used to braze the assembly. The parts are assembled and placed in the coil. Power is applied and a braze stick is used to braze the two parts in 25-30 seconds...

Soldering brass and steel radiator capsSoldering brass and steel radiator caps

The induction soldering process is completed within 15 seconds with consistent results without the use of flame, creating a safer, cooler working environment...

Preheating steel garden tools for press stampingPreheating steel garden tools for press stamping

Induction heating provides hands-free heating that involves no operator skill for manufacturing, configurable heating profiles, faster process times and even distribution of heating

Brazing a stainless steel shaft to a carbide cone for a gripperBrazing a stainless steel shaft to a carbide cone for a gripper

A three-turn helical coil is used to braze the carbide to the stainless steel shaft. A silver solder washer is placed over the post on the shaft, the carbide is placed on the washer and flux is applied...

Soldering a copper tube to a brass valve [flow valve]Soldering a copper tube to a brass valve [flow valve]

The heating process was completed within 12 seconds, faster than the client's gas torch and more reliably. Without flame, induction helps create a safer, cooler working environment.

Heating lead battery terminal for removal (recycling)Heating lead battery terminal for removal (recycling)

A single turn helical coil is used for this heating application. The lead terminal is placed inside the coil and is heated for 20 seconds.

Brazing a copper pivot assemblyBrazing a copper pivot assembly

A three-turn helical coil is used to heat the base of the assembly. The copper uprights and two braze shims are placed in the grooves in the base and black flux is applied...

Soldering a copper wire, contactor assembly [motor]Soldering a copper wire, contactor assembly [motor]

High intensity heat must be applied to the joint area for this application so that thermal conduction of the copper does not sink away the heat delivered from the induction process.

Heating a steel pipe to transport melted magnesiumHeating a steel pipe to transport melted magnesium

Induction heating provides controllable and repeatable heat pattern that keeps material in liquid form, the technology is environmentally friendly, delivering even distribution of heating . The movable workhead can be located away from the power supply

Brazing brass faucet assemblyBrazing brass faucet assembly

A two turn C shaped coil is used to braze the faucet assembly. The braze rings are placed at the joint, the parts assembled and fluxed...

Annealing Stainless Steel BraidsAnnealing Stainless Steel Braids

A specially designed multiple-turn helical coil was used to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.

Brazing a steel piston valve assemblyBrazing a steel piston valve assembly

A five turn pancake coil is used to braze the piston valve and steel plate. The assembly was heated for 10 minutes to flow the braze and join the two pieces...

Induction Annealing Springs for Stress ReliefInduction Annealing Springs for Stress Relief

Testing was successful, with a time-to-heat of 15 seconds. This client had been using an oven but was interested in changing to induction heating.

Heating magnetic iron oxide in water for hyperthermia applicationHeating magnetic iron oxide in water for hyperthermia application

Heating magnetic iron oxide (Fe2O3) in water for hyperthermia application to determine the curve of temperature vs. time during induction heating

Brazing a steel die into a wire drawing guideBrazing a steel die into a wire drawing guide

A two-turn helical coil is used for brazing the assembly. Two different bonding agents are tested for the brazing application. The first bonding agent used is braze paste. The assembly is heated to 1382 °F (750 °C) and is brazed in 45 seconds....

Hermetic Sealing a Ferrule & Fiber Optic CableHermetic Sealing a Ferrule & Fiber Optic Cable

To heat a Kovar ferrule and fiber optic cable to 297°F within 10 seconds for a soldering application, to form a hermetic seal

Annealing Copper TubingAnnealing Copper Tubing

A specially designed multi-turn helical coil was used to provide the required heat to the various copper tubes.

Heating graphite susceptor for glass reflow for X-ray tubesHeating graphite susceptor for glass reflow for X-ray tubes

A two turn helical coil is used for heating. Six graphite susceptors are placed in the nitrogen atmosphere with glass discs and a stainless steel holder.

Braze a thin walled tube to a steel cap in a hydrogen atmosphereBraze a thin walled tube to a steel cap in a hydrogen atmosphere

A single turn helical coil is used to heat the quartz tube and the tube assembly. The tube assembly is held in place inside the quartz tube by a copper fixture and hydrogen is fed into the quartz tube...

Soldering a fine copper wire to an electrical connector assemblySoldering a fine copper wire to an electrical connector assembly

induction heating delivered a higher quality joint, is more energy efficient than the outdated system that the client was using.

Braze two positions on a stainless steel manifold simultaneouslyBraze two positions on a stainless steel manifold simultaneously

A dual six turn split helical coil is used to simultaneously braze the manifold...

Soldering a steel canister for sealingSoldering a steel canister for sealing

Current hand-soldering process results in uneven, non-uniform joints and requires long production times. Induction delivers uniform, quality joints by generating heat within the end-plate and reservoir walls.

Annealing a Metal PlateAnnealing a Metal Plate

To heat a metal plate for an annealing application; the customer wanted to improve the heating time they were seeing with an open flame/torch.

Heating a steel mold for rubber seal vulcanizationHeating a steel mold for rubber seal vulcanization

Induction heating provides repeatable and consistent heat, quicker process time, increased production and even distribution of heating

Braze a carbide tip to steel cutting toolBraze a carbide tip to steel cutting tool

A split helical coil is used to heat the carbide & circular steel cutter evenly for the brazing application. The circular steel cutter is placed in a vise and the carbide and braze shim are placed onto the tooth...

Solder Fiber Optic Cable to Ferrule & PreformSolder Fiber Optic Cable to Ferrule & Preform

Induction heating provides rapid localized heat only where needed, repeatable, consistent results with clean, controllable joints

Heating Three Steel Parts for a Bending ApplicationHeating Three Steel Parts for a Bending Application

Clients are looking to upgrade cutting-tool torch brazing process with a fast, controllable and repeatable process.

Heating a steel steam trap for calibration testingHeating a steel steam trap for calibration testing

To heat a steel steam trap to 212°F (100°C) to release steam for calibration testing

Braze a mount lead to a ferrule in a PAR light bulb assembly for automobilesBraze a mount lead to a ferrule in a PAR light bulb assembly for automobiles

A split helical coil heats 2-3 ferrules at a time. The ferrules are filled with flux and the mount leads are placed inside the ferrules...

Soldering a steel funnel to flex spoutSoldering a steel funnel to flex spout

Induction heating delivers non-contact energy-efficient heat without flame, resulting in repeatable and consistent results

Heat a compacted litz wire bundle for strippingHeat a compacted litz wire bundle for stripping

A three turn helical coil is used for the wire stripping process. The litz wire bundle is placed in the coil for 3 seconds to strip the lacquer 0.75 (19mm) from the end of the bundle. The wire bundle is then scraped with a metal brush to remove the burnt lacquer...

Hermetically sealing a fiber optic cable in a kovar ferruleHermetically sealing a fiber optic cable in a kovar ferrule

Induction heating provides instant start up time, requiring very little power resources, pin point accuracy, a clean source of heat which is easily integrated into existing automated systems

Annealing a Magnetic Steel StripAnnealing a Magnetic Steel Strip

A custom-designed single position multiple-turn helical coil was built to generate the required heating for this annealing application. Initial tests were conducted to optimize the power delivered to the part.

Heating threaded area of fastenerHeating threaded area of fastener

Induction heating is localized only to the threaded area, decreases production time with a flameless process and delivers even distribution of heating

Braze electrical contacts to brass and copper busBraze electrical contacts to brass and copper bus

A five turn split helical coil is used to heat the assembly. The parts are placed 90° to the coil between the top turn and second turn with braze shims and flux.

Soldering windows to time indicator housingsSoldering windows to time indicator housings

Soldering soda lime glass metal edged windows to steel time

Annealing Copper Wire ConnectorsAnnealing Copper Wire Connectors

To anneal electrical crimp contacts of different dimensions. The client took advantage of THE LAB’s expertise to prove out their process in a way that met their time, quality and budgetary requirements.

Heating fastener blanks for thread rollingHeating fastener blanks for thread rolling

Induction heating provides faster cycle times and extended tool life with preheat step, fands-free heating that involves no operator skill for manufacturing

Braze a diamond carbide tip onto band saw bladeBraze a diamond carbide tip onto band saw blade

A single turn helical coil is used for this brazing process. The saw blade and diamond carbide tip are placed in the coil...

Soldering a copper chip to a silver dipped brass RF attenuatorSoldering a copper chip to a silver dipped brass RF attenuator

Induction heating provides repeatable consistent results in all three areas soldered at the same time, not individually. Faster process time, increased production and even distribution of heating

Annealing a Weld Seam with InductionAnnealing a Weld Seam with Induction

The client is building a system with induction. Induction achieved the client’s speed requirements and induction’s modest footprint works well within the system.With induction you can expect the same result every time.

Simultaneously heating six wire bundles to strip varnishSimultaneously heating six wire bundles to strip varnish

Induction heating provides hands-free heating that involves no operator skill for manufacturing. A multi-position coil provides simultaneous heating for quicker production times.

Braze a stainless steel braided hose to copper elbow for flexible hosingBraze a stainless steel braided hose to copper elbow for flexible hosing

A two turn helical coil is used to heat the braided hose assembly. Braze rings are placed...

Annealing a Weld Seam (Steel Assembly)Annealing a Weld Seam (Steel Assembly)

Annealing with induction required 45 seconds to heat the tube to the target temperature. This application met the client's objective

Soldering electrical wires onto three connector tabs on a three position wall socket plugSoldering electrical wires onto three connector tabs on a three position wall socket plug

Customer is currently using a soldering iron & individually touching each soldering point which is producing inconsistent results and quality issues.

Braze an end plug on a stainless steel car grillBraze an end plug on a stainless steel car grill

A three turn square shaped helical coil is used to heat the end of the grill. End plugs are inserted into the grill and the assembly is inserted into the coil for 30 seconds.

Anneal copper tubes; formed tubes & pipesAnneal copper tubes; formed tubes & pipes

Induction annealing offers the same result every time, which makes it ideal for a high volume process such as this one. The previous oxidation issue forced them to polish the handles which added a step in their manufacturing process.

Soldering 3 copper spacers to circuit board simultaneouslySoldering 3 copper spacers to circuit board simultaneously

Induction heating delivers precise, controlled application of heat in a repeatable, non-contact, clean heating process, enabling increased production capacity and improved energy efficiency

Heating a Nitinol spring assembly for shape settingHeating a Nitinol spring assembly for shape setting

Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating along the wire. The wire is heat treated on the winding machine, eliminating a secondary process

Brazing joint on pressurized heater connectorsBrazing joint on pressurized heater connectors

Brazing a joint between a copper lug and nickel plated copper pins on a pressurized heater connector.

Annealing a stainless steel handleAnnealing a stainless steel handle

The client wants to anneal a stainless steel tube while avoiding oxidation. Induction annealing offers the same result every time, copper tubes of various geometries heated to temperature in a matter of seconds, which makes it ideal for a high volume process such as this one.

Research: Heating effects on stainless steel & Tantalum discsResearch: Heating effects on stainless steel & Tantalum discs

A three turn helical coil is used to heat the discs to 1400 °F (760°C).

Brazing steel mold for golf ball dimple insertBrazing steel mold for golf ball dimple insert

Induction heating provides a no-flame process with reliable, repeatable, non contact and energy efficient heat in minimal time.

Annealing brass ammunition casingsAnnealing brass ammunition casings

The ammunition industry has been annealing with inefficient methods which require much floor space, lack consistency, create excess inventory carry costs, and don't permit in-process inspections. Brass annealing with induction ensures each and every case is quality annealed, reducing variation and damage typically found in mass annealing processes.

Heating solutions in vials for cancer researchHeating solutions in vials for cancer research

A four turn helical coil is used to heat the vial for 30 second intervals for five minutes with a temperature reading taken at each interval.

Heat aluminum for brazing an automotive assemblyHeat aluminum for brazing an automotive assembly

A multi turn pancake coil is used to heat the joint between the aluminum tubing and boss. The joint heats to temperature in 1.5 minutes and the braze ring melts forming a clean brazed joint.

Annealing stainless steel tubesAnnealing stainless steel tubes

Annealing with induction heated the client's parts to the desired temperature in less than three seconds. Their previously-used gas oven required twice as much heating time as the induction heating process. Induction annealing is more energy-efficient and requires less space compared to a gas oven.

Preheating oil drilling shaft before weldingPreheating oil drilling shaft before welding

Induction pre-heating prevents shock to shaft which eliminates cracking in the welding phase. Hands-free heating that involves no operator skill for manufacturing.

Brazing stainless steel orthodontic begg bracketsBrazing stainless steel orthodontic begg brackets

A two turn oblong helical coil is designed to heat the steel brackets which are sandwiched between the two pieces of graphite.

Shrink Fitting Steel Pipe AssembliesShrink Fitting Steel Pipe Assemblies

A specially designed multiple-turn helical coil was used to provide the required heat for the shrink fitting application

Sintering copper powder to a stainless steel shaftSintering copper powder to a stainless steel shaft

A four-turn helical coil is used to heat the assembly for five minutes. This provides slow, even heat for good penetration through the shell into the powder.

Brazing automotive tube assembliesBrazing automotive tube assemblies

A four turn split helical coil is used to heat the steel assembly to 1400°F (760°C) for 85 seconds. The coil design allows for the steel fitting to expand away from the steel tube which allows braze to flow through the joint.

Shrink Fitting a Steel Part into the CasingShrink Fitting a Steel Part into the Casing

A specially designed multiple turn internal helical coil was used to provide the heat to the various steel parts.

Bonding a Gasket to a Sombrero NutBonding a Gasket to a Sombrero Nut

A multi-turn pancake coil is used to preheat the nut. It is then transported to the next station where it is pressed onto a gasket for bonding

Brazing carbide teeth to steel pipe jaw sectionBrazing carbide teeth to steel pipe jaw section

Induction heating provides hands-free heating that involves no operator skill for manufacturing, consistent, repeatable aesthetically pleasing brazes with even distribution of heating

Annealing stainless steel tubingAnnealing stainless steel tubing

Looking to replace an inefficient oven process, a stainless steel tube is heated in just 30 seconds, improving efficiency for this application. A custom-designed single position multi-turn helical coil was built to generate the required heating for this induction annealing application

Soldering Electrical Flex CircuitsSoldering Electrical Flex Circuits

To heat multiple joints on flex circuit strips to 180-200°F within seven seconds for a soldering application.

Shrink Fitting Magnetic Steel PistonsShrink Fitting Magnetic Steel Pistons

Using induction for shrink-fitting magnetic steel pistons onto a chrome shaft; the client was using an unreliable handheld induction system and wanted a higher quality induction shrink-fitting solution.

Heating a motor prior to adding an injection molded partHeating a motor prior to adding an injection molded part

Induction heating enables quicker process times with increased production rates versus a gas-fired oven. Ovens require long heat-up and cool-down times

Braze a refrigeration tube coil assemblyBraze a refrigeration tube coil assembly

Induction heating provides the ability to direct heat only to the required zone, coil geometry which allows for easy loading and unloading of finished parts and the ability of coil to be used with water bath process allows for stability of the o-ring

Soldering a Radio AntennaSoldering a Radio Antenna

To heat a coaxial antenna assembly to 600°F within 2 seconds for a soldering application. The goal to improve on an existing procedure with a soldering iron which required 10 to 15 seconds.

Heating Hammer Bits for Shrink FittingHeating Hammer Bits for Shrink Fitting

Shrink-fitting hammer bits with induction for the insertion of carbide buttons; the end product is a drilling tool for the oil and gas industry.

Induction Bonding Metal to Plastic for Dental ToolsInduction Bonding Metal to Plastic for Dental Tools

To prepare for induction bonding, the plastic handle was slid onto the picks or mirror and placed inside the induction heating coil and heated

Brazing stainless steel tree injectorBrazing stainless steel tree injector

Induction heating provides even distribution of heating, even flow of braze alloy for an aesthetically pleasing bond and system flexibility allows for the same unit to be used for two different applications which is a cost saving.

Annealing a copper wire connector (crimp)Annealing a copper wire connector (crimp)

The client wanted to be able to anneal parts of various sizes, which was achieved with a concentrator coil. Induction annealing is a new process for the client, and Ambrell's lab expertise proved very valuable when creating the process...

Soldering Solar Flex CircuitsSoldering Solar Flex Circuits

Heat multiple joints on solar flex circuit strips to 500°F (260°C) within ten seconds for a soldering application.

Shrink Fitting a Magnetic Steel GearShrink Fitting a Magnetic Steel Gear

Induction shrink-fitting with EASYHEAT takes 45 minutes to heat the sample to the required temperature. The current oven process takes over two hours.

Induction Bonding Steel CannulasInduction Bonding Steel Cannulas

For each size cannula, the power delivered to the part was optimized to create a bond between the cannula and its bushing, without discoloring the steel of the cannula or causing the bushing to become opaque

Bulk heating a steel part prior to application of rubber moldingBulk heating a steel part prior to application of rubber molding

To preheat two irregularly shaped steel castings to be molded and bonded with synthetic rubber

Soldering three fuse caps simultaneouslySoldering three fuse caps simultaneously

Soldering three fuse caps simultaneously to reflow lead free solder and make a joint between the fuse cap and fuse wire guide

Induction Bonding Aluminum & Carbon Fiber CouponsInduction Bonding Aluminum & Carbon Fiber Coupons

To enable the process of bonding with induction, three custom-designed single position multiple-turn coils were built to generate the required heating for this application (helical, pancake and u-shaped coils).

Heat a braided cable prior to cuttingHeat a braided cable prior to cutting

To preheat two irregularly shaped steel castings to be molded and bonded with synthetic rubber

Braze four copper bus bars togetherBraze four copper bus bars together

A three-turn helical coil is used to heat the assembly. Three braze shim preforms are placed between the plates and white flux is applied to the assembly

Annealing steel wire for a medical applicationAnnealing steel wire for a medical application

Induction annealing achieved the targeted steel wire temperature within three seconds. Ambrell performed a free laboratory test, designed a cost efficient, in-house process and connected them with an automation partner to maximize productivity. The client now has better control over their end product.

Soldering three brass connectors in a solar panel junction box assemblySoldering three brass connectors in a solar panel junction box assembly

Solder three brass connectors one at a time in a solar panel junction box without affecting the components in the junction box

Bonding Steel Wire; Rubber MoldingBonding Steel Wire; Rubber Molding

To heat steel wire embedded in rubber molding for a bonding application in the automotive industry

Hermetically sealing glass-enclosed resistorsHermetically sealing glass-enclosed resistors

Induction heating provides precise, consistent heat to very small parts resulting in repeatable, quality seals. By heating with medium frequency, arcing (which occurs at high frequencies) is avoided.

Bonding Steel Tubes to Plastic Tubes with InductionBonding Steel Tubes to Plastic Tubes with Induction

Bonding with induction took just five seconds with our lowest power unit to deliver the bond just where it was needed.

Brazing a carbide and steel shank for a plug guageBrazing a carbide and steel shank for a plug guage

Induction heating provides hands-free brazing which requires no special operator skills for manufacturing, precise, even heat is applied and is divided equally, between the shank and the carbide, providing an even flow of the braze alloy as the parts reach brazing temperatures.

Annealing stainless steel caps for a dental applicationAnnealing stainless steel caps for a dental application

Our client had a requirement to anneal large quantities of work-hardened stainless steel crowns. Induction was suggested for its precise, controllable heating. Since oxidation is unacceptable in the finished dental product, induction heating is the appropriate choice for heating in an inert atmosphere.

Soldering a steel cover onto a nickel plated EMI filterSoldering a steel cover onto a nickel plated EMI filter

Soldering a nickel plated steel cover onto a nickel plated steel EMI filter housing without damaging the RF circuit

Shrink Fitting of BearingsShrink Fitting of Bearings

A multi-turn helical coil delivers uniform heat to the entire range of the bearing sizes in the transverse mode.

Induction Tempering a SpringInduction Tempering a Spring

Energy is applied directly to the springs only; surrounding air and fixturing are not heated.

Debonding Rubber Gaskets, End RingsDebonding Rubber Gaskets, End Rings

It took a modest amount of time to debond the rubber gasket from the metal end ring in this release/debonding induction application. Heat is delivered only where needed.

Braze steel O-ring Face Seal fittings to a steel tubeBraze steel O-ring Face Seal fittings to a steel tube

A four-turn 2.75 inch (7.0 cm) ID helical coil is used for heating both the steel tube and the ORFS sleeve or the ORFS male connector.

Annealing brass and bronze tubing prior to bending to form handrailsAnnealing brass and bronze tubing prior to bending to form handrails

Employing brass annealing with induction to form tubes into handrails, a twelve-turn helical coil was used to heat an 8”x3” (20.3cm x 7.6cm) area above the end of the tubes. Each of the four tubes require a different heat cycle and time to reach the required temperature.

Shrink Fitting an Aluminum Tube (optical system)Shrink Fitting an Aluminum Tube (optical system)

With an EASYHEAT 2 kW induction shrink-fitting system, the aluminum tube heated to the required temperature within 30 seconds. Shrink fitting then took place

Heating aluminium susceptor for powder expansionHeating aluminium susceptor for powder expansion

Expand powder into solid form for use in crash helmets

Induction Bonding Adhesive to a Steel Washer (Automotive)Induction Bonding Adhesive to a Steel Washer (Automotive)

Bonding with induction heated a steel washer to the target temperature to enabling adhesive curing; it will be part of an automated process for an automotive industry application

Steel-carbide brazing cutting toolSteel-carbide brazing cutting tool

The body shim and carbide are cleaned and braze flux as applied to the entire surface of the assembly. The parts are placed together in the induction coil.

Annealing a zinc wire prior to forming pellets for air riflesAnnealing a zinc wire prior to forming pellets for air rifles

A fourteen-turn coil is used to heat 3.9” (100mm) of zinc wire for this zinc wire application. The wire is placed in the coil for 5 seconds to reach the desired condition just prior to the forming process.

Soldering 2 electrical wires to copper buss barSoldering 2 electrical wires to copper buss bar

Induction heating delivers reduced solder time, even distribution of heating and improved joint-to-joint consistency

Shrink fitting an automotive aluminum motor housingShrink fitting an automotive aluminum motor housing

Induction shrink-fitting is fast, presents significant energy savings over an electric oven, requires a more modest footprint than an oven and can be easily integrated into an automated process

Metal-to-Plastic Insertion with a Brass ShaftMetal-to-Plastic Insertion with a Brass Shaft

Multiple torches were required for this application previously, so the compact EASYHEAT minimized the required footprint for heating. With induction you can expect the same result every time, while variability is often observed with a torch

Heating steel liners (engine head)Heating steel liners (engine head)

Precise direct heat to disengage the aluminium quickly and cleanly. The aluminium casing is recycled and reused thereby reducing scrap and cutting costs.

Induction Bonding Plastic with a Steel Gasket (Automotive)Induction Bonding Plastic with a Steel Gasket (Automotive)

Induction bonding enables rapid heating, can easily be integrated into the client's manufacturing process due to modest space requirements and delivers a highly repeatable process.

Brazing carbide to steel for a surgical deviceBrazing carbide to steel for a surgical device

Compared to a stick-fed flame braze heating, induction heating provides consistently higher quality joints. This is critical for medical applications.

Annealing the end of a hydraulic motor shaft prior to machiningAnnealing the end of a hydraulic motor shaft prior to machining

A three-turn helical coil is used to anneal the steel hydraulic motor shaft. The end of the motor shaft is placed in the coil and power is applied for 20 seconds to reach 1350 °F (732 °C) and turn the steel red hot before machining.

Soldering an LED assembly to an aluminum spotlight housingSoldering an LED assembly to an aluminum spotlight housing

A multi turn pancake coil is used to heat the bottom of the aluminum spotlight housing. The LED housing was not available so this application is done with temperature sensing paint to determine the feasibility

Inserting a Steel Bushing to an Aluminum HubInserting a Steel Bushing to an Aluminum Hub

The client currently uses an electric oven and the heating time is two hours, so at 60 seconds, the time savings with induction shrink-fitting is very significant

Metal-to-Plastic Insertion with a Steel InsertMetal-to-Plastic Insertion with a Steel Insert

The power was turned on for five seconds and the part was monitored during heating and for 15 seconds after.

Conveyor steel plate heatingConveyor steel plate heating

Heat steel plates on conveyor system in order to cook Welsh cakes.

De-bonding a Magnetic Steel Paint Can LidDe-bonding a Magnetic Steel Paint Can Lid

The goal of the induction bonding process is to quickly and cleanly remove the can lid and to pour out paint to reformulate. Induction enabled rapid removal of the paint can lids.

Brazing a Plumbing Union in Tight QuartersBrazing a Plumbing Union in Tight Quarters

Induction provides a reliable braze joint obtained under limited-access conditions, energy is applied only to the joint; little energy is lost to surrounding parts and flame is not used; no bottled gasses required

Annealing aluminum fuel tank fill neck for bendingAnnealing aluminum fuel tank fill neck for bending

An eight-turn helical is used to heat the aluminum tube for annealing. To anneal the full length of the tube, the tube is placed in the coil and heated, and then the tube is bent while hot to prevent cracking.

Heating a Steel Pin for Fan InsertionHeating a Steel Pin for Fan Insertion

An EASYHEAT and its workhead require a minimal footprint, saving the client valuable floor space compared to heating alternatives

Soldering connector to wire harnessSoldering connector to wire harness

Induction heating provides reduced production cost, faster process time, hands-free heating that involves no operator skill for manufacturing

Forming a Large Steel TubeForming a Large Steel Tube

Heating an area around elliptical hole in steel tube prior to forming; the client had been using a torch for this application.

Heat steel pliers handle for bendingHeat steel pliers handle for bending

Precisely heating the desired zone avoids overheating of part. This provides higher quality vs. heating with a torch.

Bonding a Stainless Steel Sheet to a Soundproofing MatBonding a Stainless Steel Sheet to a Soundproofing Mat

The part was assembled with the mat in contact with the stainless steel sheet. The part was set on non-conductive material, and placed inside the coil.

Brazing a Brass Trap BlockBrazing a Brass Trap Block

induction heats only the material within the coil; no energy is wasted heating the surrounding materials and air; no flame or gasses required for heating

Annealing of stellite tips on saw bladesAnnealing of stellite tips on saw blades

To anneal the affected zone of a saw blade after the stellite tips have been welded in place, a split four-turn helical coil is used to allow the blade to move evenly through the coil. Each tip of the blade is heated for 5 seconds as it passes through the coil to anneal the affected area.

Heating Steel Inserts for Metal-to-Plastic InsertionHeating Steel Inserts for Metal-to-Plastic Insertion

It took 5 seconds with a 2 kW EASYHEAT to reach temperature, which melted the plastic for a solid bond without cracking the molded plastic.

Soldering two connectors simultaneously to gound plateSoldering two connectors simultaneously to gound plate

Induction heating provides non-contact heat, hands-free heating that involves no operator skill for manufacturing with even distribution of heating

Hot Heading Steel Wire: Create ScrewsHot Heading Steel Wire: Create Screws

Preheating steel wire before hot heading to create a screw; they wanted to switch from cold heading to extend tool life.

Curing Oil Filters for Agricultural EquipmentCuring Oil Filters for Agricultural Equipment

To heat steel parts for a curing application; the end-product was an oil filter for agricultural equipment.

Brazing Faucet Components, AssembliesBrazing Faucet Components, Assemblies

Three helical coils are used separately to braze a range of provided parts. Parts are assembled with flux and a braze alloy and then heated.

Continuous annealing of copper wireContinuous annealing of copper wire

To anneal a copper wire used in electric motors, a twelve-turn helical coil is used with an inserted ceramic tube to isolate the copper wire from the coil and to allow the wire to flow smoothly through the coil. Power runs continuously to anneal at a rate of 16.4 yds (15m) per minute.

Heating four brass inserts prior to insertion into a plastic motor housingHeating four brass inserts prior to insertion into a plastic motor housing

Using induction heating, the parts came to the required temperature in just 15 seconds in a highly repeatable heating method and a coil plate could offer protection against operator movement/errors

Curing coatings; steel tube, aluminum blockCuring coatings; steel tube, aluminum block

The client's oven had a heating time of 20 minutes, so the time savings from a 90-second cycle are considerable. Additionally, induction is a repeatable process, unlike an oven and the induction system takes up less floor space than an oven.

Soldering fabric to kovar tip assemblySoldering fabric to kovar tip assembly

A three turn pancake coil is used to heat the tip of the cone to 300 °F (149 °C) in 2-3 seconds

Shrink Fitting A Gear to a Shaft (Automotive)Shrink Fitting A Gear to a Shaft (Automotive)

The customer was using a torch, which can lead to inconsistent part quality. Induction's precise heating means the client can count on consistent results in their process

Heating Cutting Tools for ForgingHeating Cutting Tools for Forging

An infrared pyrometer was used to monitor the temperature of the part during the heating cycle. Two parts were tested.

Heat aluminum molds to release baked food productsHeat aluminum molds to release baked food products

Induction heating is safer than heating with a convection oven. Grease from the molds causes a fire hazard and waste gases in the oven.

De-Bonding Urethane From A Steel Insert (Doffer Pad)De-Bonding Urethane From A Steel Insert (Doffer Pad)

A three-turn pancake style coil is used to de-bond urethane from the steel disc. The part is placed onto two 0.10 (2.5mm) thick ceramic rods on top of the coil and heated for 15 seconds...

Brazing Brass Fitting to Copper TubeBrazing Brass Fitting to Copper Tube

For larger copper tube assemblies, the same process is used, but the braze alloy is stick-fed to the joint to prevent the alloy from flowing out of the joint.

Annealing lip on cryogenic dewarAnnealing lip on cryogenic dewar

A two-turn helical coil is used to heat the lip on the cryogenic dewar. The dewar is placed in the coil and power is applied for 2 minutes to anneal the required 1 heat zone...

Heating stainless steel inserts for an insertion applicationHeating stainless steel inserts for an insertion application

Induction offers dramatically faster heating when compared to ultrasonics; faster heating means there is the potential to dramatically increase production rates with a highly repeatable and easy-to integrate processes.

Soldering a kovar piece with glass to a copper base for a photon light sourceSoldering a kovar piece with glass to a copper base for a photon light source

Induction heating provides ability to use same equipment for both assembly and repair, hands-free heating that involves no operator skill for manufacturing, and uniform control of heat from part to part

Shrink Fitting an Aluminum Motor HousingShrink Fitting an Aluminum Motor Housing

The customer was using a cold press, but it was creating part defects. This was resolved with induction heating: the process took just two minutes compared to 40 minutes and they were able to achieve their targeted production rate.

Curing Epoxy On A Laser Diode AssemblyCuring Epoxy On A Laser Diode Assembly

To heat epoxy on a laser diode assembly to 250°F within 5 seconds for a curing application

Flattening/Bending Steel TubesFlattening/Bending Steel Tubes

Induction forging elevates the temperature much more rapidly than an oven, targeting the precise portion of the part that requires heating every time, presenting a significant advantage over an oven

Heat twelve steel tubes simultaneouslyHeat twelve steel tubes simultaneously

The coil is comprised of two (2) six-position helical coils connected together in parallel to reduce the voltage requirements on the power supply.

Debonding inserts for manifoldDebonding inserts for manifold

A four-turn two-position helical coil is used to debond the inserts from the plastic. The coil is placed against the manifold and power is applied to the two inserts for 15 seconds to soften the plastic...

Brazing Carbide Tips to a Meat CutterBrazing Carbide Tips to a Meat Cutter

Due to the size of the induction coil, the process allows for precise placement of the carbides on the steel shanks

Anneal an oval cut-out on a stainless steel tube prior to extrusionAnneal an oval cut-out on a stainless steel tube prior to extrusion

To anneal a ¼” area around an oval cutout on a stainless steel tube prior to extrusion, a single-turn helical coil is used on the 4 (101.6mm) diameter tubes and a two turn helical coil is used on the smaller diameters.

Heating brass inserts for metal-to-plastic insertionHeating brass inserts for metal-to-plastic insertion

Innovation: Ambrell's Applications Lab was able to solve a problem that a competitor couldn't solve, which is a key benefit when purchasing induction solutions from Ambrell

Soldering brass and copper (anesthetic medical equipment)Soldering brass and copper (anesthetic medical equipment)

This process is completed in two steps that use a 3 turn helical coil. The first process is to solder the brass ring to the copper piece which takes 85 seconds...