Precision Induction Brazing INDUCTION HEATING SOLUTIONS

Brazing is Ideal for Many Applications in Manufacturing. What is Brazing? Brazing is a process for joining two metals with a filler material that melts, flows and wets the metals’ surfaces at a temperature that is lower than the melting temperature of the two metals. Protection from oxidation of the metal surface and filler material during the joining process is achieved using a covering gas or a flux material. Brazing and silver soldering are terms that usually refer to the joining process where the filler materials have a melt temperature above 400°C (752°F) to create a stronger joint. Why...

Replacing Torch and Furnace Brazing with Induction Brazing • Torch brazing is the most common form of brazing today, but requires a skilled operator. However many manufacturers are finding it harder to recruit experienced brazing operators and the open flame raises regulatory and safety concerns for manufacturing plants. • Furnace brazing is another widely used technique. Manufacturing companies today are looking to improve production efficiency, reduce manufacturing costs and replace energy and space inefficient furnaces while improving product quality. • Induction addresses the issues of torch...

Braze Filler Materials and Fluxes The function of braze filler material is to provide a metallurgical bond to the surfaces of the materials on both sides of the joint. There are many different braze alloys that are designed to correctly melt, flow, wet out and bond materials for joining. Typical braze filler materials that are used to create the correct alloy for the joint materials are copper, silver, zinc, nickel and aluminum. Some filler material alloys have eutectic properties that are very useful for the brazing process where the alloy melts and flows at a lower temperature than the melt...

A Smarter Brazing Solution Whether you’re concerned with throughput, part quality or manufacturing efficiency, induction heating is the ideal brazing method for your process The Induction Brazing Process Induction brazing is used in the joining of many different metals for multiple applications. Typical joints are steel-tosteel, steel-to-brass, steel-to-copper, copper-to-copper, aluminum-to-aluminum and copper-to-aluminum. The Six Steps to a Quality Induction Brazed Joint: 1. Design the joint correctly allowing for a 40µm (0.0015”) to 125µm (0.005”) clearance between the two surfaces at the braze...

Every Brazing Application is Customized Ambrell products are custom-designed to fit each customer’s unique application. Our systems are continually replacing outdated heating methods worldwide for their speed, consistency and precision. Brazing Applications Manifold Assembly Brazing Replacing torch brazing for assembling a manifold for an air conditioner is a two-step induction brazing process. First, the four aluminum tubes are brazed into the aluminum manifold using an elongated coil in 60 seconds with 3.5 kW at 180 kHz to 566°C (1050°F). Copper-to-aluminum brazing is the second step and it...

Aluminum Brazing Applications Aluminum requires a lot of energy to heat using induction and its thermal conductivity is 60% compared to copper. Coil design and time for the heat to flow is critical in a successful induction brazing process for aluminum parts. Recent advances in lower temperature aluminum braze materials has allowed induction to effectively replace flame and furnace heating in high volume brazing of aluminum assemblies. The low melt temperature of aluminum requires that the induction brazing process apply the energy to the part correctly to raise both part surfaces to the braze...

Steel Brazing Applications Induction brazing is the ideal technique for joining steel parts where welding is not suitable. A well-designed induction brazed steel joint provides many benefits including part geometry integrity and lower part stress. Carbon and stainless steel have high resistivity – they couple well to induction energy and heat easily. However, they have poor thermal conductivity so the induction brazing of steel parts should not be rushed. With steel, it is important the heat is given time to soak through to the joint surface for proper flow and wetting out of the braze material....

Only with Ambrell will you get the experience you need for precision brazing applications. Steel, Copper and Brass Brazing Induction brazing is an excellent method of joining parts made of dissimilar metals. Applications with mixed metal joining include steel-to-copper, steel-tobrass and brass-to-copper. With these materials, it’s all about timing. For a successful brazed joint between different metals it is critical that both metal surfaces reach the braze flow temperature at the same time as the joint. The induction heating solution must take into account the different thermal conductivities...

Ambrell Induction Heating Systems at a Glance With our EASYHEAT™ and EKOHEAT® we offer a wide power and frequency range with our induction heating systems. Whether you’re brazing large or small parts or multiple metal materials, Ambrell can help you maximize cost efficiencies and productivity. Systems Include: Ambrell’s systems are versatile with multiple capacitor and tap transformer configurations. They offer efficient power conversion that will minimize your energy costs. Our systems are user-friendly, offer agile frequency tuning for repeatable heating, and can be easily integrated into your...

Free Application Testing From THE LAB With a Reputation for Delivering Extraordinary Results, Our Applications Laboratory is the Gold Standard in the Industry. Our Applications Laboratory – known in the industry as THE LAB – is where we solve our customers’ most challenging heating applications every day. Dr. Girish Dahake, Sr. Vice President, Global Applications, leads a worldwide team of elite engineers who are uniquely qualified to assist you with your heating process needs. Under the guidance of Dr. Dahake, our engineers have evaluated thousands of applications in THE LAB, so it’s likely...