Induction Brazing of Hydraulic Fittings
Induction brazing of hydraulic fittings overview
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. Steel typically has a high resistivity - therefore it couples well to induction energy and heats easily. However, the thermal conductivity is usually low 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.
The Inductelec temperature control system ensures that the component is heated at the optimum rate to ensure through heating around and across the brazed joint whilst minimising scale formation of the surface of the components.
What is induction brazing?
Brazing is a process of joining closely fitted metal components together that uses a filler metal (and usually an anti-oxidizing solvent called flux) without melting the base materials. Instead, induced heat melts the filler, which is then drawn into the base materials by capillary action.
Focus on induction brazing of hydraulic fittings.
Features of Machine
- Optimised heat times for different component sizes – up to 50% heat time saving
- Capacity to component from 6mm diameter to 75mm diameter
- Pyrometer based temperature control system to ensure accurate, controlled heating of the component
- Soak time is optimised to ensure maximum throughput and minimal scale formation
- 30 kW power unit
- Air blast cooling for induction system
- Work coil
- Data logging so process parameters can be stored for every component processed
- Identification of different component sizes and recipes applicable automatically loaded into PLC
Operation of System
- Components are cleaned to remove any grease from joint area
- Flux is applied to both components where joining is to occur
- Components are assembled together with braze material in place
- Assembly is loaded into dedicated tooling
- Components are identified, and correct recipe automatically loads
- Heat cycle is started with optimised heat time
- Heat cycle ends
- Brazed assembly is unloaded from tooling
- Heat parameters are stored for review and traceability
What are the Benefits?
- Energy efficiency
- Accurate and repeatable delivery of heat
- Uniform heat giving predictable brazed joints
- Precise control of cycle times ensuring minimal scale formation
- Minimised heat times for each component size
- Temperature control is accurate with precise control of ramp-up times and holding temperatures
- Data logging giving the output parameters of every component produced
- Fewer reject parts as all aspects of the process can be monitored
- Ease of integration into an existing production cell
- Better quality
- Only narrowly defined areas are heated, leaving adjacent areas and materials unaffected
- Correctly brazed joints are strong, leak-proof and corrosion resistant
- Joints are very neat, usually requiring no further milling, grinding or finishing