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A custom-designed single position multi-turn helical coil was built to generate the required heating for the application.
The client requested a system that would meet their time objectives which the EKOHEAT easily did, boosting the client’s throughput.
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.
Heat steel cutting bits with diamond-carbide inserts for brazing and de-brazing; the end products are cutting tools
This configuratoin achieved the client’s objective. The channel coil – specially designed by THE LAB at Ambrell– was critical to the application’s success.
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.
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.
Produces repeatable, rapid and accurate heating cycles making it ideal for in-line production processes
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
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
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
Induction completed the carbide brazing process more rapidly than an oven, delivering heat exactly where it’s needed, operating instant on/instant off
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.
To heat a nickel sleeve and a copper mast for a brazing application to create a pitot tube for the aerospace industry
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...
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
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.
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.
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.
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
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
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
The proposed process met the client’s time objective, and is faster than oven heating.
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.
The client wanted to heat three parts concurrently, and this process allowed up to five parts to be heated concurrently...
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
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
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
Induction results in faster heating than a torch with faster, multipart heating to increase output.
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.
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.
Precise, repeatable heating: The client wanted more precise and repeatable heating than a torch could deliver, which induction was able to achieve..
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...
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.
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.
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.
In this copper brazing process, induction offers more precise, repeatable heating than current flame process.
Induction heating achieves superior process repeatability when compared to a brazing torch and a more predictable aerospace parts which enhances quality.
Induction heating is used to braze a steel connector onto a steel tube to create a hydraulic component. ...
Induction heating is used to achieve client’s goal to braze both stainless steel parts as quickly as possible with maximum repeatability.
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.
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.
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.
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
Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating precise and controllable heat.
The customer is currently using a torch to complete the braze joints. They wish to improve repeatability for a better process.
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.
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.
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...
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...
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.
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.
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.
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.....
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.
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.
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.
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.
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.
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.
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.
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.
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.
A dual six turn split helical coil is used to simultaneously braze the manifold.
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.
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.
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.
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.
A single turn helical coil is used for this brazing process. The saw blade and diamond carbide tip are placed in the coil.
A two turn helical coil is used to heat the braided hose assembly. Braze rings are placed.
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 a joint between a copper lug and nickel plated copper pins on a pressurized heater connector.
Induction heating provides a no-flame process with reliable, repeatable, non contact and energy efficient heat in minimal time.
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.
A two turn oblong helical coil is designed to heat the steel brackets which are sandwiched between the two pieces of graphite.
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.
Induction heating provides hands-free heating that involves no operator skill for manufacturing, consistent, repeatable aesthetically pleasing brazes with even distribution of heating
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
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.
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
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.
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.
Compared to a stick-fed flame braze heating, induction heating provides consistently higher quality joints. This is critical for medical applications.
Compared to a stick-fed flame braze heating, induction heating provides consistently higher quality joints. This is critical for medical applications.
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
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
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.
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.
Due to the size of the induction coil, the process allows for precise placement of the carbides on the steel shanks
With induction, energy is applied only to the zone to be heated heating of the joint/braze is uniform and repeatable
Two sets of parts are placed in the individual coils. Braze preforms are placed on the cone at the joint.
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.
Induction heating delivers reduced ring warping compared to furnace heating and decreased cycle time due to reduced ramp-up and cooldown times
Hardsolderen is een verhittingsproces waarbij twee of meer soortgelijke of ongelijke materialen samengevoegd worden door middel van een andere metaallegering met een lager smeltpunt. Hardgesoldeerde verbindingen kunnen uitzonderlijk sterk gemaakt worden, soms sterker dan de twee metalen die samengevoegd worden. (De term 'zilversolderen' wordt soms gebruikt om te verwijzen naar zilverhardsolderen.)
Hardsoldeerverbindingen zijn vloeistof- en gasdicht, kunnen schokken en trillingen weerstaan, worden niet beïnvloed door normale temperatuurschommelingen, zorgen voor goede elektrische geleidbaarheid en kunnen gemakkelijk beplaat worden met gebruik van conventionele processen. Typische hardsoldeertemperaturen variëren tussen 426 °C - 1177 °C (800 °F en 2150 °F).
Moderne inductieverhitting geeft betrouwbare, reproduceerbare, contactloze en energie-efficiënte warmte in een minimale tijd zonder vlam. Solid-state-systemen zijn in staat heel kleine zones binnen preciese productietoleranties te verhitten, zonder de metallurgische eigenschappen te verstoren. Voor toepassingen met groter volume en/of kwaliteitsafhankelijke processen kunnen onderdelen hardgesoldeerd worden met inductie onder een gecontroleerde atmosfeer zonder flux of enige bijkomende schoonmaakstappen. Typische inductiestroomvoorzieningen voor hardsolderen variëren van 1 tot 20 kW, afhankelijk van de onderdelen- en toepassingsvereisten.
Hardsolderen: De legering kan in smeersel, voorvorm of stokvorm zijn, afhankelijk van de toepassing. Een draadvoorvorm krijgt in het algemeen de voorkeur omdat deze zorgt voor een gelijkmatige verdeling en de consistentie las-tot-las bevordert. Verschillende hardsoldeerlegeringen hebben verschillende verhittingseigenschappen; zilver wordt vaak gebruikt voor hardsolderen omwille van het laag smeltpunt ervan. Zilver-koper eutectische hardsolderingen hebben smelttemperaturen tussen 599 °C - 899 °C (1100 °F en 1650 °F). Aluminumhardsoldering, de minst voorkomende, heeft een smelttemperatuur van 565 °C - 615 °C (1050 °F tot 1140 °F). Koperhardsoldering, de goedkoopste, heeft een smelttemperatuur van 704 °C - 1177 °C (1300 °F tot 2150 °F).
Flux: De functies van flux zijn het ontbinden van de oxiden die tijdens het verhittingsproces worden gevormd, het beschermen van de legering en verbinding tegen oxidatie, het zorgen voor schone oppervlakken om gelijke verspreiding van de legering te bevorderen en het bevorderen van legeringstroom door het fenomeen van capillaire werking geassocieerd met oppervlaktespanning en leidend tot de verhoging of verlaging van vloeistoffen in capillairen. Er zijn veel verschillende soorten fluxen beschikbaar voor gebruik bij verschillende temperatuurbereiken. Zwarte flux wordt gebruikt voor hoge temperaturen (tot op 982 °C of 1800 °F) en is geschikt voor het hardsolderen van staal. Witte flux wordt het vaakst gebruikt voor toepassingen bij lagere temperatuur (593 °C - 815 °C of 1100 °F - 1500 °F). Idealiter zou de flux een lager smeltpunt dan het basismetaal moeten hebben en volledig vloeibaar moeten zijn voordat de hardsoldeerlegering smelt.
Warmtebron: Snelle, preciese inductiehitte werkt het best.