Induction Brazing Aluminum

Induction brazing addresses the issues of torch and furnace brazing by removing the requirement for a skilled operator, by reducing energy costs and by decreasing the equipment footprint while implementing a lean manufacturing process for higher quality parts.

 

 

Induction Brazing Aluminum

Induction brazing addresses the issues of torch and furnace brazing by removing the requirement for a skilled operator, by reducing energy costs and by decreasing the equipment footprint while implementing a lean manufacturing process for higher quality parts.

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.

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brazing aluminum with Induction Application Notes

Click to read how brazing aluminum with induction can improve the efficiency, effectiveness and safety of your heating process.

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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.

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...

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...

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..

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...

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...

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

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

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

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

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

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

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 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

Heating aluminium susceptor for powder expansionHeating aluminium susceptor for powder expansion

Expand powder into solid form for use in crash helmets

Sealing an aluminum disk onto a plastic capSealing an aluminum disk onto a plastic cap

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.

Cap Sealing; Shampoo ContainerCap Sealing; Shampoo Container

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.

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 Catheter Tipping DieHeating Catheter Tipping Die

To heat an aluminum catheter tipping die to above 2850F within 2 to 5 seconds for the forming of catheter material.

Curing Alumium Car MoldingCuring Alumium Car Molding

Automotive manufacturers are constantly searching for cost-effective production technologies.

Curing ink on aluminum bottle capsCuring ink on aluminum bottle caps

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.

Curing plastisol adhesive on an aluminum filter assemblyCuring plastisol adhesive on an aluminum filter assembly

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.

Curing epoxy on aluminum copier roller assemblyCuring epoxy on aluminum copier roller assembly

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.

Curing a coating; both sides aluminum pistonCuring a coating; both sides aluminum piston

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.

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

Reflowing the solder of an area on a circuit boardReflowing the solder of an area on a circuit board

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 aluminum in a graphite crucible for castingInduction Melting aluminum in a graphite crucible for casting

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.

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

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

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

Induction heating 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

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 is very significant

Shrink-fitting auto turbo charger impeller blades onto an aluminum shaftShrink-fitting auto turbo charger impeller blades onto an aluminum shaft

Induction heating provides repeatable results, reduced cycle time, lower consumables cost and even distribution of heating

shrink-fitting aluminum pulley to insert inner bearingshrink-fitting aluminum pulley to insert inner bearing

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.

Heating Aluminum Auto Trim for Adhesive CuringHeating Aluminum Auto Trim for Adhesive Curing

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.

Bonding Foil to a Plastic BottleBonding Foil to a Plastic Bottle

It was confirmed that the aluminum heated sufficiently to create a bond between the foil and the bottle, meeting the client’s objective.

Bonding Aluminum & Carbon Fiber CouponsBonding Aluminum & Carbon Fiber Coupons

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).

Sealing an Aluminum Cap Seal on a Plastic JugSealing an Aluminum Cap Seal on a Plastic Jug

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.

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

Other Aluminum Brazing Resources:

Select from our in-depth materials to help you better understand the benefits brazing aluminum with induction heating can bring to your process.

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.

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About Induction Heating

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.

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Induction Heating Work Coils

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