Ambrell Induction Heating
Ambrell Induction Heating
induction brazing benefits

Induction Brazing

Brazing is a process for joining two metals with a filler material that melts, flows and wets the metals’ surfaces at a temperature that is lower than the melting temperature of the two metals. Protection from oxidation of the metal surface and filler material during the joining process is achieved using a covering gas or a flux material. 

Brazing with induction is ideal for your heating process, combining the precision, control, economics and safety inherent in the technology. Ambrell has more than 12,000 systems installed in over 50 countries, and many of them employ our induction brazing equipment. It’s our most common application that is used daily, worldwide, in many different industries.

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100+ Brazing Application Notes

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Brazing a Copper Tube and Brass Fitting (fuel containment)

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

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 Steel Tube with External Wire Braid

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

Brazing and De-Brazing Diamond Carbide Inserts

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

Brazing 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 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 rectangular steel part

Induction is able to rapidly heat the 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 copper to brass (heat exchanger)

Produces repeatable, rapid and accurate heating cycles making it ideal for in-line production processes

Brazing a steel and copper strip to carbide

Heating 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

Brazing a rectangular steel part

Heating 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

Brazing a copper tube

The client had been using a torch, which took 50 seconds instead of 30; induction 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 a copper block and carbide to create a contact shoe assembly

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

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 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

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 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

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 efficiency; a good braze joint was formed, and induction’s consistency and repeatability proved valuable

Brazing 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 braze joint was formed, and induction’s consistency and repeatability proved valuable. Induction doesn’t employ an open flame, which results in a safer work environment

Brazing copper tubes to a brass manifold block

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

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.

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...

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 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

Brazing 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

Brazing a steel and brass immersion heating element

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

Brazing 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.

Brazing a magnetic steel tube and steel mating assembly

Heating a 0.437" (11.1 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.

Brazing an aluminum manifold for an conditioning industry application

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

Brazing 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...

Brazing 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 ºF (704 ºC) within five seconds for a brazing application to create a part that governs the armature position in a motor.

Brazing a steel rod and sensor housing assembly

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

Heat 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.

Brazing a copper elbow tube assembly

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

Brazing 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.

Brazing a steel tube and fitting assembly

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

Brazing two 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 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 heat.

Brazing 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.

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 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...

Brazing a carbide to a stainless steel shaft 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 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.

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 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.

Brazing 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.

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 carbide cone to a stainless steel shaft 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.

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 ºF (750 ºC) and is brazed in 45 seconds.

Braze 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.

Braze two positions on a stainless steel manifold simultaneously

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

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.

Braze 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.

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.

Braze electrical contacts to brass and copper bus

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

Braze 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.

Braze 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.

Braze 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.

Brazing joint on pressurized heater connectors

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

Brazing 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.

Heat 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.

Brazing 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.

Brazing automotive tube assemblies

A four turn split helical coil is used to heat the steel assembly to 1400ºF (760ºC) 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.

Brazing 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

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.

Braze 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.

Steel-carbide brazing cutting tool

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

Brazing 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.

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 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.

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 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

Brazing Copper Fittings to Refrigeration Valve

With induction, energy is applied only to the zone to be heated heating of the joint/braze is uniform and repeatable

Brazing a Cutting Tool Assembly

Two sets of parts are placed in the individual coils. Braze preforms are placed on the cone at the joint.

Brazing carbide rotary file to high speed steel shanks

A multi-turn helical coil is used. The part is heated to determine the time required to reach the desired temperature and required heat pattern.

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


More Brazing Resources:

Select from our libraries of materials to help you better understand the benefits brazing with induction heating can bring to your process.

Important Induction Heating Brochures

411-0169-10

About Induction Heating

Induction heating is a fast, efficient, precise and repeatable non-contact method for heating metals or other electrically-conductive materials. The material may be a metal such as brass, aluminum, copper or steel or it can be a semiconductor such as silicon carbide, carbon or graphite. To heat non-conductive materials such as plastics or glass, induction is used to heat an electrically-conductive susceptor, typically graphite, which then transfers the heat to the non-conducting material.

Read our 4-page brochure; learn more about how the science of induction technology can solve your precision heating problems.

Read 'About Induction Heating'

411-0168-10

Induction Heating Work Coils

The work coil is the component in the induction heating system that defines how effective and how efficiently your work piece is heated.

Provide a little of your business contact information to read our informative brochure explaining the fundamentals of the induction work coils and their design.

 

Read 'Induction Heating Work Coils