Brazing and soldering soldering refers to the joining of two or more components using a special filler material and heat. Although very similar in nature there are fundamental differences in the two processes defined by the temperature and the metallurgical reaction between the filler and base metals.
In soldering the metal filler will typically have a melting temperature of less than 450°C and an intermetallic phase is formed in the joint area. In the brazing process the metal filler has a melting temperature in excess of 450°C and solid solutions are formed in the joint area.
The principle advantages of Induction Heating in Brazing applications are as follows:
All Induction Brazing systems feature the same principle elements as follows:
In its simplest form the induction brazing system will be a generator a coil and a cooler. The system is manually fed and the operator assembles all the component parts places them in the coil and initials the braze cycle. However in order to maximise throughput a variety of techniques and systems can be employed.
Mutiple Head Systems
In the multi head system the power unit is equipped with more than one work-head and a power changeover system to switch the generator power to either work-head in turn. This allows load unload to take place at the station which is not being heated whilst brazing takes place at the other station often removing the load unload time from the process.
In line conveyors are often utilised in high volume situations where a skid coil can be used the conveyor can be either an indexing type or run at a constant speed subject to the application.
As with the conveyor the rotary table can be used for many brazing applications and can be either an indexing type or a constant speed version subject to coil geometry and other application based criteria.
Both the rotary table and the conveyor based units can be equipped with a variety of ancillary equipment including bowl feeders, pick and place units, quality monitoring devices and solder and flux dispensers to increase the level of automation.
Induction Brazing - Case Study Multi Head System
Application - Confidential.
Component Details - 5mm brass to 3mm Copper.
Process Requirement - Braze copper wire to bore of Brass Tube.
Induction Equipment - UT 111 200 12kW 200kHz Ultra-Tec power unit with twin low impedance safe-braze work-heads and auto changeover system.
Feed System - IHG 571 TSBS Twin head brazing system, featuring specially designed low pressure pneumatic clamp tooling for accurate positioning of the component to be brazed. Input to the system was manual using a pre-assembled component and a pre-formed solder ring. The system featured PLC control with a recipe based setting system utilising a Mitsubishi HMI with error trapping on all critical parameters. Work coils, IWC 12 air-blast cooler & Extraction system.
Induction Brazing - Case Study Rotary System
Application - Induction Brazing.
Component Details - Electrical contacts.
Process Requirement - Join Silver tip to Brass or Copper sub component.
Induction Equipment - 2XUT 111 50 5kW 100kHz Ultra-Tec power units.
Feed System - IHG2534 MPRT Multi station rotary table based brazing system. The system features an 8 position rotary table complete with automatic braze paste dispenser, pick and place component assembly, twin braze station and QC station. Operator protection was via a light guard and fume extraction was provided at the braze station. The system featured PLC control with a recipe based setting system utilising a Mitsubishi HMI with error trapping on all critical parameters. Work coils, IWC 10 air-blast cooling systems.
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