This customer-requested demonstration proved that by using induction to braze the copper assemblies, the customer would achieve consistent and repeatable results, with high energy- and cost-efficiency of the brazing process.
The time- and energy-efficient induction brazing for copper parts has been recently demonstrated by UltraFlex Power Technologies. UltraFlex, who is a leading manufacturer of advanced, digitally controlled induction heating solutions, had set up this test application per request of a customer in the HVAC industry.
The customer was a manufacturer specialized in the production of refrigerated food displays who was considering replacing his current, torch-based brazing processes with induction brazing. The samples he provided to evaluate the results from an induction-based brazing had different shape and size - a 3/8" tube with a 3/8" coupler, a 1/2" Swedged tube, and a 5/8" Swedged tube. The customer requirements were to use the same-size heating coil for all samples to be brazed, and to keep the heating cycles within 10 to 20 seconds per joint.
For this induction brazing scenario, UltraFlex engineers recommended the use of an induction heater from the UltraFlex UltraHeat W series, along with an UBraze handheld gun. UltraHeat W are advanced, cost-effective 5-15 kW Induction Heating systems utilizing the latest switching power supply technology. They feature adaptive digital phase control providing very efficient operation in a wide frequency range. UBraze is the UltraFlex mobile induction heating solution. Its accurate energy control allows you to work with precision and to accurately determine the time and power needed for each joint.
The demonstration was split into two tests - one for the smaller pipes and one for the larger-sized pipes and involved manual feeding of the brazing alloy. At target brazing temperature of 1600°F (871°C) and 7 kW of power applied, it took only 15 seconds to braze the smaller pipes and only 20 seconds to braze the bigger ones. By increasing the power output to 10 kW, the heat cycles would be even shorter. The usage of preformed rings would allow repeatability for the process.
The demonstration proved that by using induction to braze the copper assemblies, the customer would achieve consistent and repeatable results, with high energy- and cost-efficiency of the brazing process. In addition, this would be a time-efficient process, allowing the customer to increase productivity rates. Finally, with no open flame, smoke or noxious emissions, the induction brazing would be a safe process - safe for the operator, safe for the environment.
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About UltraFlex Power Technologies:
UltraFlex Power Technologies (ultraflexpower.com) offers the most advanced and innovative digitally controlled induction heating equipment in the industry. Its compact modular and flexible systems are used for a wide variety of induction heating, casting and melting applications.