Note: Brazing aluminum electrical lug assembly

Objective:

Brazing a aluminum bracket to an aluminum lug to create an electrical lug 

End Product:

Lug

Equipment:

Ambrell 6 kW induction heating system, equipped with a remote workhead containing two 1.5μF capacitors for a total of 0.75μF An induction heating coil designed and developed specifically for this application.

Materials:

Aluminum bracket 1.73 in (43.9mm) long, .68 in (17.2mm) wide & .21 in (5.3mm) thick aluminum lug 3.98 in (101mm), .81 in (20.6mm) wide & 0.1 in (2.5mm) thick aluminum  braze stick 

Temperature:

650 °F (343 °C)

Frequency:

159 kHz

Testing:

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

Benefits:

  • Ability to heat very small areas within tight production tolerances

  • Clean leak-proof joints‚Quickly delivers localized heat to minimize warping and distortion of part

  • Consistent temperature vs. flame brazing

Brazing aluminum electrical lug assembly

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