How Are Induction Brazing Machines the Ultimate Solution to Brazing Problems?
September 26, 2024
The ultimate brazing solution facilitates control and optimization of the manufacturing process, leading to higher quality products and increased market share. Investing in induction brazing machines significantly enhances this process.
These machines use induction heating to melt the filler metal, allowing for the joining of two materials (metals/alloys) in a close-fitting space without melting the base material. Flux is typically employed to prevent oxidation at the brazed joint. The filler metal is melted through induction heating and drawn into the gap between the base metals via capillary action.
Induction brazing machines produce high-quality water and airtight joints with minimal oxidation, resulting in cleaner joints compared to flame brazing technology. This precision makes induction brazing particularly suitable for joining small components, including electronic parts and radio frequency collectors.
It is usually composed of the following:
Induction Generators; used to produce electric power
Proper Coils Design
Feeder Units; can be automatic, semi-automatic, or manual
Nitrogen Installation for protective gas atmosphere during brazing
Water cooling of brazing chamber and fixtures
Water re-cooling system
Fixtures
PLC control system
Induction brazing machines offer a superior solution for industrial brazing, with three basic types outlined below:
This portable, high-frequency magnetic induction machine is designed for brazing copper tube pipes on-site. In the tool industry, hardfacing alloys are commonly applied using this method. Induction brazing of synthetic and natural diamond grits occurs at around 1080°C for 30 seconds, resulting in a strong bond without the need for a vacuum or hydrogen furnace. These portable machines are favored for their lightweight design, efficiency, and ability to produce high-quality joints.
This machine strikes an ideal balance between speed, flexibility, and cost-effectiveness. While the operator handles component assembly and flux application, the brazing process is automated. The automotive industry increasingly adopts semi-automatic induction brazing machines for high-volume production, such as brazing pegs into gas filter caps.
Automated induction brazing systems enhance metal applications, improving product quality and reducing labor costs and rejection rates by minimizing human error. Industries like HVAC require various brazed joints during fabrication. These energy-efficient systems can produce approximately 25,000 parts per month, with each part taking around 30 seconds. Automated machines feature a turntable with 16 sample holding positions, allowing for increased repeatability and productivity. The precise control provided by automated equipment reduces production losses by optimizing power and temperature settings.
In the realm of induction brazing, the materials being joined are of significant importance. Induction brazing machines can effectively braze a wide variety of materials, including stainless steel, steel, carbon steel, titanium, copper, silver, aluminum, Kovar, molybdenum, and cement.
For instance, carbon steel gas filters feature two separate induction-brazed joints on either side, requiring precise control of the heat zone. In turbine blade fabrication, titanium is brazed in a hydrogen environment.
Copper tubes in modular compressor assemblies typically have 7 to 8 induction-brazed joints, demonstrating the technology’s versatility for various sizes. This process successfully braze components such as copper cylinders to copper wire, copper sections to copper spacers, and small copper pipes.
Aluminum tubes are brazed to flanges (bases) for batteries using induction brazing to ensure optimized heat distribution, allowing for effective filler flow without melting the components. For example, aluminum tubing can be brazed with an aluminum receiver in less than 15 seconds. Additionally, magnetic steel belts can also be brazed using this technology.
Induction brazing can also join different metals. For example, brass fittings can be brazed to copper tubes for HVAC systems. A specialized cable featuring gold wire cladding with stainless steel and a glass conductor core has shifted to induction brazing due to its reliability and safety. While the productivity rate may be lower, the shorter heating cycles optimize the overall process.
Induction brazing machines are facilitated in numerous fields, such as:
Aerospace Industry: Hydraulic lines, turbine blades
Automotive & Transportation: Heat exchangers, shafts, plates fittings, gas filter components, electrical vehicle batteries, valve assembly, brake lines etc.
Electrical Engineering: Short-circuit rings
Toolmaking Industry: Carbide cutting tips
Home Appliance Industry: Copper wires
Air Conditioning Industry: HVAC-system
Fittings Industry: Carbide pins for high-pressure grinding rolls, brass and stainless steel couplers, Diverter valve
Generator /Power Plant construction
Manufacturing and Automation Industry
Oil & Gas Industry: Special cables (stainless steel-gold-glass conductor core), high-pressure fuel lines, fuel fillers
Induction brazing is an efficient technique that lowers energy costs, enhances repeatability and productivity, reduces maintenance needs, minimizes floor space, and eliminates operator variability.
This ultimate induction brazing solution enables operators to conduct processes within predefined parameters and set more precise limits, ensuring consistent quality, productivity, and profitability without compromising safety. Additionally, brazing machines can be tailored to meet the specific manufacturing requirements of various industries.
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