What Is Induction Soldering?
Induction soldering is a process in which a precise electromagnetic field is used to heat two or more electrically conductive materials in order to join them with a filler material that melts at a temperature below the melting point of the joined materials. Induction soldering delivers precise, localized heat, increases production rates with faster heating cycles and reduces defect rates with repeatable, reliable heating, eliminating variability from part to part, while maintaining metallurgical characteristics of the individual metals.
Free Induction soldering Application Notes
To heat customer assemblies for a desoldering application. The client had been outsourcing this task, but wanted to see if it would be viable to bring the process in house.
A solder wire preform was placed on the part to allow for repeatable placement of solder in every joint. Four top or four bottom joints will be heated at one time within 2-3 minutes for the soldering application.
To heat a glass feed-through inside a copper block for a soldering application, one side at a time. This was a new application/process for the client.
To heat ferrule and module assemblies for a soldering application in the fiber optics industry.
Given the small size of the part and the assembly's geometry, a graphite cylinder was required as a susceptor.
The solder formed a relatively uniform domed seal around the fiber despite the asymmetry of the open C coil. It took under 10 seconds to heat the part to soldering temperature
Soldering with Induction takes under 10 seconds to heat four copper strips concurrently, resulting in a boost in throughput for the client. Induction is a highly repeatable process that heats just the area of the copper strip that requires it
Soldering with induction required under 10 seconds and is a highly repeatable process; the customer can expect the same result every time with only the portion of the part requiring heating being heated.
Soldering with induction proved faster than the client's previous heating torch process. It is also is a repeatable heating process, so the client gets superior results and is more energy efficient than torch heating.
Induction's precision soldering ensures repeatable results and less damage to surrounding substrates while demonstrating reduced heat loss and lower energy usage...
For this grounding lug soldering application, induction delivers consistent result is achieved each time and does not present a flame, so it helps create a safer, cooler working environment than other methods
The induction soldering process is completed within 15 seconds with consistent results without the use of flame, creating a safer, cooler working environment...
The heating process was completed within 12 seconds, faster than the client's gas torch and more reliably. Without flame, induction helps create a safer, cooler working environment.
High intensity heat must be applied to the joint area for this application so that thermal conduction of the copper does not sink away the heat delivered from the induction process.
To heat a Kovar ferrule and fiber optic cable to 297°F within 10 seconds for a soldering application, to form a hermetic seal
induction heating delivered a higher quality joint, is more energy efficient than the outdated system that the client was using.
Current hand-soldering process results in uneven, non-uniform joints and requires long production times. Induction delivers uniform, quality joints by generating heat within the end-plate and reservoir walls.
Induction heating provides rapid localized heat only where needed, repeatable, consistent results with clean, controllable joints
Induction heating delivers non-contact energy-efficient heat without flame, resulting in repeatable and consistent results
Induction heating provides instant start up time, requiring very little power resources, pin point accuracy, a clean source of heat which is easily integrated into existing automated systems
Soldering soda lime glass metal edged windows to steel time
Induction heating provides repeatable consistent results in all three areas soldered at the same time, not individually. Faster process time, increased production and even distribution of heating
Customer is currently using a soldering iron & individually touching each soldering point which is producing inconsistent results and quality issues.
Induction heating delivers precise, controlled application of heat in a repeatable, non-contact, clean heating process, enabling increased production capacity and improved energy efficiency
To heat multiple joints on flex circuit strips to 180-200°F within seven seconds for a soldering application.
To heat a coaxial antenna assembly to 600°F within 2 seconds for a soldering application. The goal to improve on an existing procedure with a soldering iron which required 10 to 15 seconds.
Heat multiple joints on solar flex circuit strips to 500°F (260°C) within ten seconds for a soldering application.
Soldering three fuse caps simultaneously to reflow lead free solder and make a joint between the fuse cap and fuse wire guide
Solder three brass connectors one at a time in a solar panel junction box without affecting the components in the junction box
Soldering a nickel plated steel cover onto a nickel plated steel EMI filter housing without damaging the RF circuit
Induction heating delivers reduced solder time, even distribution of heating and improved joint-to-joint consistency
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
Induction heating provides reduced production cost, faster process time, hands-free heating that involves no operator skill for manufacturing
Induction heating provides non-contact heat, hands-free heating that involves no operator skill for manufacturing with even distribution of heating
A three turn pancake coil is used to heat the tip of the cone to 300 °F (149 °C) in 2-3 seconds
Induction heating provides ability to use same equipment for both assembly and repair, hands-free heating that involves no operator skill for manufacturing, and uniform control of heat from part to part
This process is completed in two steps that use a 3 turn helical coil. The first process is to solder the brass ring to the copper piece which takes 85 seconds...
Induction heating provides hands-free heating that involves no operator skill for manufacturing, lends itself well to automation, solder controlled by preforms, no excess left on board, good solder flow without over heating the board
A dual four turn pancake coil is used to solder 2 brass caps per cycle. Liquid solder is squirted onto the end cap and is heated for 18 seconds at 302°F (150°C) to burn off the flux
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 heating delivers increased production rate due to speed of heating, higher quality vs. a soldering iron due to precision and repeatability and cost savings due to reduced scrap and higher quality production
Compared to using a manual soldering iron, induction heating precisely applies heat to for higher quality solder joints This is ideal for integrating with an automated system. By stick- feeding the solder more aesthetically pleasing parts are produced.
A multi-turn helical coil is used and temperature-indicating paint is applied to the joint area. The wire assembly is placed over the induction heating coil, and RF power is applied.
With an efficient coil design induction heating easily reaches the desired reflow temperature in a very short amount of time.
Heat a.125 (3.175mm) diameter stainless steel tube to a 1 diameter cylinder 1 (25.4mm) tall for a soldering application
A two-turn induction coil is used to deliver the heat energy into the steel housing. A small diameter solder wire is used to form a solder ring for the assembly process...
Soldering two brass tubes measuring 3/4-inch and 1/4-inch together for use as cellular phone antennas. The lengths of tubes range from four (4) feet to twelve (12) feet, and must be soldered along the axial side.
To heat a section of 3/8 inch copper tubing along with a 90 degree elbow for soldering. The copper tubing is to be used in Ice Machine Evaporator Assemblies, and soldering takes place after the tubes have been placed within the assembly.
To heat a brass bellows and end cap assembly to 450F for soldering within 20 seconds. Presently, a soldering iron is used to produce the joint between the bellows and cap.
Heat an assembly of small, gold-plated steel connectors to a brass block, heating to specific regions of part
To heat 1.75, 3 and 6 inch diameter brass slip rings and a sheathed copper wire assembly to 360F for soldering within three (3) to six (6) seconds. Currently production is accomplished by using a soldering iron and stick feeding rosin-cored solder...
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Why use induction for soldering?
Induction soldering delivers energy only where it's needed, so it delivers faster heating times, reduces potential for process error, enhances process control and saves energy.
How does soldering differ from brazing?
Soldering is performed at lower temperatures than brazing and may result in a slightly weaker joint, but one that's preferable for some applications such as those involving small components.
Can soldering and brazing be done with one system?
The amount of power available in the induction system determines if you can use the same system.
What materials can be soldered with induction?
Induction soldering is a highly effective method specifically designed for joining electrically conductive materials. It offers exceptional results when working with materials like copper, brass, steel, and aluminum. This technique utilizes electromagnetic induction to generate heat, which is then applied to the workpiece, melting the solder and creating a strong bond between the materials. The advantage of induction soldering lies in its ability to precisely control the heat distribution, ensuring a uniform and reliable connection. Additionally, this process minimizes the risk of thermal damage to the surrounding areas due to its localized heating feature. By harnessing the power of induction soldering, manufacturers can achieve efficient and high-quality soldering for a wide range of applications in industries such as electronics, automotive, and plumbing.