Brazing is widely used in a range of manufacturing industries. It is a process where we use a filler metal to join two or more pieces of metal together. You can join a wide range of metals, even ferrous to non-ferrous.
Depending on the desired properties, a variety of alloys are used as filler metals, but they all have a lower melting point than the adjoining metals. When heated, the melted filler flows between the close-fitting metal pieces that are being joined, interacting with a thin layer of the base metal to form a strong, leak-proof joint that usually doesn’t require secondary finishing.
Brazing differs from other comparable metal-joining processes like welding in that it does not involve melting the workpieces, and from soldering in that it requires a higher temperature and more closely fitted parts.
Many different heating methods are available for brazing operations. Traditionally, gas-fuelled furnaces and blowtorches are most commonly used.
With induction technology, the heat comes from an electromagnetic field that is created by the alternating currents from an induction coil. It is a no-contact process and the base metal never comes into contact with the heat source. In fact, induction produces heat within the base metal itself—and nowhere else.
The process is incredibly fast. However, precision and speed are only two of the many advantages of using induction heating for industrial brazing. Other benefits of this eco-friendly technology include better and more consistent joint quality, reduced oxidation and need for cleaning, suitability for large volume production, energy efficiency, and a safer and more comfortable working environment.
Faster and better – every time
Induction heating is fast, controllable, repeatable and easy to automate. Just enter the desired time and temperature and the induction equipment will repeat the heating cycles—again and again. Since the induction heating cycle is normally very short in comparison to flame brazing, more parts can be processed in the same amount of time, resulting in a quicker throughput and a higher production volume.
With induction brazing, only narrowly defined areas are heated, leaving adjacent parts unaffected. The controlled heat minimizes distortion and warpage, and there is less danger of hydrogen embrittlement.
The carefully controlled induction heating process also allows operators to view the brazing procedure, whereas trying to see through a white-hot flame can be very difficult, particularly since the operator is required to wear protective glasses and a mask.
Open flames create uncomfortable and hazardous working environments for several reasons. In contrast, induction is quiet, clean and safe. There is virtually no increase in ambient temperature, and it is easy to extract fumes.
Even though it transfers a lot more energy per square millimetre than a flame, induction takes less time, heats only a defined area of the material and uses less energy to do the same job. With induction brazing, you get a clean, strong, leak proof joint, suitable even for high-precision instruments and other equipment that requires high reliability.