Induction brazing
ENRX offers brazing in various fields, such as the automotive, aviation, electrotechnical and white goods industries.
Introduction
Brazing is a material-joining process that uses a filler metal, and usually an anti-oxidizing solvent called flux, to join two pieces of metal together without melting the base materials. Instead, induced heat melts the filler, which is then drawn into the base materials by capillary action.
- Join a wide range of metals, even ferrous to non-ferrous
- Heat only narrowly defined areas
- Ideal for integration into production lines
Brazing basics
What is brazing?
Type of braze joints
Different heat sources can be used for brazing:
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Induction
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Resistance heaters
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Ovens and furnaces
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Torches/flame
There are three common brazing methods:
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Capillary
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Notch
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Moulding
Induction brazing is concerned solely with the capillary method.
What is brazing?
Type of braze jointsÂ
Heat sources and brazing methods
Different heat sources can be used for brazing:
- Induction
- Resistance heaters
- Ovens and furnaces
- Torches/flame
There are three common brazing methods:
- Capillary
- Notch
- Moulding
Induction brazing is concerned solely with the capillary method.
Soldering
Induction heating is also used in soldering, a process similar in many ways to brazing. Soldering, however, uses much lower temperatures (below 450°C) than brazing (typically 450 - 1150°C). Induction soldering offers many of the same benefits as induction brazing: high heat density, short heating times, minimal heat seepage to adjacent components, no-contact heating, and controllability.
Induction brazing step by step
Before you start
Some questions should be investigated—and answered—in order to assure successful, cost-effective joining.
For instance:
- How suitable are the base metals for brazing?
- What type of braze joint should be designed?
- What coil design best meets specific time and quality requirements?
- Should the brazing process be manual or automatic?
- Is edge polishing and deburring necessary?
At ENRX, we address these critical points and more before recommending a brazing solution.
The brazing process
The induction brazing process can be divided into the following steps:
- Ensure the correct gap between the base materials.
- Clean the base materials by removing residues, oxides, etc.
- Apply flux to the joint area.
- Position and, if necessary, clamp the parts to be brazed in place.
- Apply the brazing filler alloy.
- Induce the desired heat in the joint area.
- Remove any remaining oxides or flux residue after brazing is complete.
What can we braze?
If you want to join any of these materials, chances are ENRX can devise a brazing Âsolution tailored to your exact requirements.
- Copper
- Steel
- Brass
- Aluminium
- Stainless steel
- Iron
- Hard metal
- Tungsten/Wolfram
- Carbides
- Chromium
- Diamonds
- Nickel
- Cobalt
- Noble metals
- Stellites
Image gallery
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Induction brazing of brake linings
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Induction heating is a perfect method for high troughput brazing of evaporator and condenser connections
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Induction brazing of aluminium parts
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ENRX has unrivalled expertise in making efficient solutions for aluminium brazing.
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Induction brazing of compressor parts
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Induction is a high troughput, no-contact heating method. It helps ensure strong yet barely visible joints-and the oustanding aesthetics expected by today's customers.
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High-quality banjo nipples being brazed under a controlled atmosphere in a customised ENRX brazing machine.
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Induction brazing steel support bars for sofas.
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Induction brazing of cable shoe.
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Devising brazing systems for carbide tips, blades and bits is an ENRX specialty.
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A contactor being induction brazed
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Controlled atmosphere brazing at an ENRX production facility. This method is increasingly used for large-volume production of high-quality, mission-critical components.
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Brazing of a copper tube to an aluminium heat exchanger. Note the automatic filler material feeder
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Induction brazing is fast, precise, clean, energy-efficient, controllable and repeatable.
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Induction brazing of generator windings
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Induction brazing of heat distributor
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Induction brazing of heat distributor
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Induction brazing of heating element
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Induction brazing of refrigerator parts. Note the convenience of our handheld heat output unit.
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Induction brazing of a microphone.
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Induction brazing of pole windings
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A stationary coil during brazing of a short-circuit ring for one of the world’s leading power generation equipment companies
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Induction brazing of short-circuit rings
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Bars of silver filler about to be heated for brazing bars to a short-circuit ring. Once heated to the correct temperature, the filler will appear to “float” on the surface of the metal, before being drawn evenly into the joint by capillary action.
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Usually, the strongest joints are made by allowing just enough space for the filler metal to flow into the joint area. Wider spacing will generally result in a weaker joint.
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Fast, precise, controllable and easy to use. Induction isperfect for faucet brazing—whether it’s tube-to-socket, tube-to-tube or thread insert brazing
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Iinduction heating is the perfect choice for brazing bars, strands, rings and wires in motors, generators and transformer. This photo shows brazing of strands.
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A manual loading/unloading system for brazing of contactors.
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Brazing of stator and rotor windings. Brazing components in high-voltage step-up transformer.
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Brazing of terminal ends on high voltage cable
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Brazing components in high-voltage step-up transformer
