Brazing aluminum requires a lot of energy to heat using induction and its thermal conductivity is 60% compared to copper. Coil design and time for the heat to flow is critical in a successful induction brazing process for aluminum parts. Recent advances in lower temperature aluminum braze materials have allowed induction to effectively replace flame and furnace heating in high volume brazing of aluminum assemblies.
brazing aluminum with Induction Application Notes
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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.
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...
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...
Precise, repeatable heating: The client wanted more precise and repeatable heating than a torch could deliver, which induction was able to achieve..
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...
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...
The polymer coating on the aluminum strip behaved differently when heated. Visually, the coating turned brown and bubbly when the aluminum strip was heated
Induction does not present an open flame into the work environment like a torch, resulting in a safer working environment
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
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
Given the significantly faster heating time, induction improves throughput in this process and is a more efficient heating method than hot plate heating
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
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.
Through heating the top 2 (50.8mm) of aluminum oxygen tank to form a rounded end with a hole for oxygen valve
Expand powder into solid form for use in crash helmets
Induction heating enabled the aluminum to seal to the plastic cap quickly without the cap being damaged. The customer desired a quick rate which would make in-sourcing the process worthwhile, and induction heating exceeded the targeted production rate thanks to its fast heating.
A three-turn two-position helical coil is used to heat the aluminum foil in a tunnel style assembly. Product (containers) passes easily under the induction coil.
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.
To heat an aluminum catheter tipping die to above 2850F within 2 to 5 seconds for the forming of catheter material.
Automotive manufacturers are constantly searching for cost-effective production technologies.
A double channel coil is used for the ink drying application. Fifteen bottle caps are placed inside the coil and power is applied for 3 seconds to dry the ink.
A four turn helical coil is used to cure the plastisol adhesive. One filter end cap is filled with adhesive, attached to the filter and heated 90 seconds to cure the adhesive.
A four turn helical pancake coil is used to heat the end of the copier roller assembly. The assembly is heated 90 seconds to cure the adhesive.
A three turn channel coil 19 (48.26cm) long is used to anneal 4 pistons running though the coil with a distance of 6 (15.24cm) between centers.
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
An aluminum fixture is a large heat sink to the induction field. In order for solder alloy to wick and run the length of the overlap area, flux is applied to the solder location...
Induction melting provides hands-free heating that involves no operator skill for manufacturing, repeatable, dependable results, more efficient and cost effective then gas furnace, does not heat up the manufacturing area and increases production.
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
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
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
Induction heating provides repeatable results, reduced cycle time, lower consumables cost and even distribution of heating
A three turn helical coil is used to heat the aluminum pulley. The pulley is heated to 464 °F (240 °C) in 20 seconds to expand the inner diameter and then the inner bearing is inserted to form the completed part.
To heat various sizes of aluminum auto trim to 500°F (260°C) at a rate of 30 ft. (9.1m) per minute for curing an adhesive.
It was confirmed that the aluminum heated sufficiently to create a bond between the foil and the bottle, meeting the client’s objective.
Three custom-designed single position multiple-turn coils were built to generate the required heating for this bonding application (helical, pancake and u-shaped coils).
To heat one aluminum cap seal on a plastic jug for a cap sealing application. The client is replacing past systems that no longer work for their process.
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
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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.
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.
Read our informative brochure explaining the fundamentals of induction coils and their design.