Brazing a Copper Tube and Steel Plate
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 a Nickel Pin and a Nickel Wire
To braze a nickel pin and a braided nickel wire; the end-product is a heater assembly. Results in improved joint quality compared to using flame heating
Brazing a Steel and Carbide Assembly
To braze a steel and carbide assembly to create a mining bit for the oil and gas industry; the client is replacing their torch process with induction
Brazing 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.
Brazing 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 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.
Brazing 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
Induction 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
How 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
Brazing 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.
Brazing 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 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...
Brazing 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...
Brazing 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.
Brazing 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
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 efficienc; a good braze joint was formed, and induction's consistency and repeatability proved valuable
How 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
Brazing 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 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...
Brazing 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...
Brazing 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
Brazing 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 heatŚ
Brazing 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...
Brazing 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.
Brazing 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...
Brazing 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...
Brazing 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...
Brazing 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.....
Brazing 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...
Brazing 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...
Brazing 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...
Brazing 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...
Brazing 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....
Braze 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...
Heat 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...
Brazing 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.
Braze 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
Brazing 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.
Braze 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
Brazing 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.
Steel-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.
Brazing 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
Brazing 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
Brazing 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.
Brazing Diamond Drill Inserts
Induction heating delivers reduced ring warping compared to furnace heating and decreased cycle time due to reduced ramp-up and cooldown times
Brazing a carbide shaft to steel tube
Induction heating provides even, precise heat. Precise directed heat is required for the solder braze to flow evenly around the part to assure a good joint.
Brazing a Bourdon Tube Assembly
To braze a thin copper oval tube to a brass fitting at 1400 ° F and to cap the other end of the copper tube with a brass plate.
Brazing steel dental tools
To heat a steel tip and shank assembly to 1300°F (704°C) within 3 seconds for brazing with induction heating instead of torch brazing.
Brazing Copper Tube Assemblies
To heat a copper tube assembly in an inert atmosphere to 1450°F within 45 seconds for brazing without flux or acid wash clean-up.