UltraFlex induction brazing demo for copper, brass and steel proves the energy- and time-efficiency of the induction brazing process

PUBLISHED: 28 Sep 18

UltraFlex induction brazing demo for copper, brass and steel proves the energy- and time-efficiency of the induction brazing process
UltraFlex induction brazing demo for copper, brass and steel proves the energy- and time-efficiency of the induction brazing process

In a series of tests, UltraFlex Power Technologies - manufacturer of the most advanced digitally controlled induction heating solutions in the industry - demonstrated the induction-based brazing process for 4 different types of assemblies: copper to copper, copper to brass, copper to steel, and brass to steel assembly. The company shared the brazing time and heating parameters used for each test, proving the energy- and time-efficiency of the induction brazing process.

All 4 tests aimed at achieving a target brazing temperature of 1200°F to 1400°F+ (648°C to 760°C+). The induction heating was supplied by an UltraFlex proprietary 25-35 kW induction heating equipment from the UltraHeat M series. The UltraHeat M series feature adaptive digital phase control providing very efficient operation in a wide frequency range, capability to deliver full power in the 10-150kHz frequency range, power control from 10 to 100% in 1% increments and much more.

The copper to copper test aimed at brazing 2 copper pipes of 2.14" (54.35mm) and 2.25" (57.15mm) outside diameter, inserted into each other. At power of 30.6 kW, the entire brazing cycle was completed within mere 30 seconds.

The copper to brass test was carried out on an assembly having 1.66" (42.16mm) outside diameter, 0.06" (1.52mm) thick wall, 1.56" (39.62mm) long. The heat cycle was started with lower 7 kW power output then raised to 19.03 kW in a span of 30 seconds, to prevent damage to the part. The power was then lowered to 15.36 kW over the next 10 seconds, leaving it the same over the next 25 seconds to ensure full alloy flow. The entire brazing process took 65 seconds to complete. The brazing time could be reduced to 20 seconds or less if full power was applied at the beginning, but monitoring for potential part damage would be then required.

In the third test, copper tube of 2.15"(54.61mm) outside diameter had to be brazed to steel tube of 1.98" (50.29mm) outside diameter, with a 2.5" (63.5mm) flange. This test was done using 16.21 kW starting power, increasing it to 23.27 kW over the course of the test, to prevent overheating of the steel ring. The brazing process was completed within 35 to 40 seconds.

The brass to steel test required brazing of brass fitting with 1.85" (46.99mm) inside diameter and 2.35" to 2.9" (59.69mm to 73.66mm) outside diameter to steel with 1.8" (45.72mm) inside diameter and 1.98" (50.29mm) outside diameter, with 2.5" (63.5mm) flange. This fourth test was conducted with a starting power of 7.39 kW, raised to 14.93 kW. It was then lowered to 11.17 kW to prevent overheating of the steel ring or the edges of the brass.

All tests required rotating of the parts to allow for even heating. A handheld coil would allow easy regulation and spread out of the heat by the end user.

The test results shared by UltraFlex proved that the use of induction heating for brazing different materials was both energy and time-efficient. Further optimizations related to the quality of the brazing process and time consumed to complete it were easy to identify and apply for the purpose of production line brazing.

Ultraflex Power Technologies, USA
Tel: + 1 631 467 6814
Email: sales@ultraflexpower.com
Web: www.ultraflexpower.com

More news from this company:
UltraFlex brazing stainless steel to copper tubes within 9-11 seconds using Induction Heating
New demonstration by UltraFlex shows the efficiency of induction heaters for bore heating of steel pipes
UltraFlex induction brazing demo for copper, brass and steel proves the energy- and time-efficiency of the induction brazing process
UltraFlex induction heaters solder brass tube to galvanized steel pans within 25 seconds
UltraFlex successfully brazing aluminum rails radiators using induction heating
UltraFlex announces the release of their breakthrough SmartPower Compac Systems
Un-brazing and re-brazing copper angle brackets to copper strips at 760°C in less than a minute
Using Induction Heating to simultaneously solder two brass tubes to a brass water jacket assembly within 70 seconds
Brazing corrugated tubing to stainless steel pipe and cap using UltraFlex Induction Heating
Brazing of heat exchanger pipes
Induction braze copper and brass lap joint
Preheat magnetic steel strip with very even heating across the strip
Induction heating system delivered for automotive parts supplier
Soldering copper pins onto a PCB
Induction preheating of brass rods before hot forging