Improved Soldering with Induction Heating

Soldering Applications with Induction Heating ISO Emblem Using Induction

» What is Induction Heating Induction heating is a method of providing fast, consistent heat for manufacturing and research applications which involve bonding or changing the properties of metals or other electrically conductive materials. The process relies on electrical currents within the material to produce heat. Although the basic principles of induction are well known, modern advances in solid state technology have made induction heating a remarkably simple, cost-effective heating method for applications which involve joining, treating, heating and materials testing. The basic components...

» What is Soldering? Induction soldering is an induction process in which two separate pieces are fused together using a filler metal or other material that melts at a temperature below 427 ºC (800 ºF). The filler metal varies depending on the other components being joined, but the most common fillers for induction soldering include alloys such as tin-silver, tin-zinc, and tin-lead. Soldering differs from brazing because it is performed at lower temperatures. When compared to brazing, soldering may have a slightly weaker joint, but that can be preferable for some applications such as those involving...

» Advantages of Induction Heating Improved Productivity Improved Energy Efficiency Improved Design; Integration Improved Features • Meets tight production tolerances with precise localized heat to small areas creating pinpoint accuracy • Increases production rates with faster heating cycles • Reduces defect rates with repeatable, reliable heat • Eliminates variability from operator-to-operator, shift-to-shift • Maintains metallurgical characteristics of the individual metals • Uses less energy-immediate heating • Non-contact heating • Generates heat only where needed; no wasted energy • Produces...

» Soldering Four Fusible Copper Strips OBJECTIVE To heat copper strips of various sizes to 400 ºF (204 ºC) for a soldering application; the client was heating two fusible strips concurrently but would like to heat four concurrently with induction. EQUIPMENT Ambrell EASYHEAT™ 5 kW, 150-400 kHz induction heating system equipped with a remote workhead. A single position four turn double wound helical coil designed specifically for this application. 175 kHz 400 ºF (204 ºC) Copper strips and solder. Initial tests were conducted to optimize the power delivered to the copper strip. Four parts were placed...

» Soldering a Pair of Magnetic Steel Pins OBJECTIVE To solder a pair of magnetic steel pins/posts to create an automotive component. EQUIPMENT Ambrell EASYHEAT™ 1 kW, 150 to 400 kHz induction heating system equipped with a remote workhead containing one 1.33 μF capacitor for a total of 1.33 μF. A single-position two-turn pancake induction heating coil designed and developed specifically for this application. Coil and steel pin assembly (5/16”/7.9 mm pin/post O.D.) and solder rosin core. Any remaining insulation on the wire was removed with sand paper. A foot peddle was part of the induction heating...

» Soldering a Fine Copper Wire to a Connector Assembly OBJECTIVE To solder a smaller copper wire and connector assembly within one second, and a larger assembly within two seconds for a battery cable and terminal application for the automotive industry. Ambrell EASYHEAT™ LI 3542, 4 kW, 150-400 kHz induction heating system equipped with a remote heat station containing one 1.5 μF capacitor. A single position, three-turn helical induction heating coil. A single position, four-turn double wound helical induction heating coil was used for smaller assemblies. Smaller copper wire (OD of 0.41mm/0.02”)...

» Soldering Steel Canister Reservoir for Sealing OBJECTIVE Induction offers benefits over a current hand-soldering operation of these beverage dispenser reservoirs. Ambrell EASYHEAT™ 2.4kW/300kHz induction heating system, equipped with a remote workhead containing two 0.33μF capacitors for a total of 0.66μF. An induction heating coil designed and developed specifically for this application. 248 kHz 500 ºF (250 ºC) Steel canister (reservoir), 6inch x 4 inch oval, end plates. Current hand-soldering process results in uneven, non-uniform joints and requires long production times. Induction delivers...

» Soldering a Copper Wire and Contactor Assembly OBJECTIVE To heat a copper wire and contactor assembly to 400 ºF for a soldering application at a motor manufacturer. Ambrell EASYHEAT™ 5kW 150-400 kHz induction heating system equipped with a remote work head containing two 1.0 μF capacitors. A multi-turn helical induction heating coil designed and developed specifically for this application. 360 kHz 400 ºF (204 ºC) Rotor assemblies and solder 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...

» Soldering a Copper Tube to a Brass Flow Valve OBJECTIVE To heat a copper tube and a brass valve to 356 ºF for a brazing application. EQUIPMENT Ambrell EASYHEAT™ 9kW 150-400 kHz induction heating system equipped with a remote work head containing two 1.5 μF capacitors. A single-position two-turn C-shaped induction heating coil designed and developed specifically for this application. Copper tubes (various sizes), brass valves (various sizes), solder and general purpose flux The assembly was placed into the induction heating coil and the power was turned on. After 12 seconds solder was fed to...

» Soldering Brass and Steel Radiator Caps OBJECTIVE To heat brass and steel radiator caps to temperature for a soldering application. Ambrell EASYHEAT™ 9kW 150-400 kHz induction heating system equipped with a remote workhead containing two 1.0 μF capacitors. A single-position two-turn split helical induction heating coil. • Brass radiator caps • Steel radiator caps • Solderand Flux For the brass cap, the Ambrell team found that by varying the position of the part axially in the coil, more or less heat could be applied to the top or bottom of the assembly. A position was found to heat the top...