Application Note Objective
Induction brazing is a popular application in the Automotive industry. UltraFlex was contacted by a major manufacturer who wants to improve cycle times with the help of a semi-automated induction heating system. Our team was provided with 0.75’’ (19 cm) OD aluminum rod and 1.16’’ (29.4 cm) x 2.72’’ (69 mm) x 0.92’’(23.3 mm) aluminum base used for the production of Brake and AC Lines and in Hydraulic Lines.
We utilized our UltraHeat SM – 5 kW air-cooled induction heating system to fit the process requirements. It has a built-in thermal regulator with a pre-programmed temperature profile featuring multiple steps of ramps and holds times.
The aluminum part was nested in a piece of nonconductive insulation brick with a hole drilled in the middle. The thermoregulator of the UltraHeat SM – 5 kW induction heating system was equipped with a dual-color R Series IR Pyrometer. Brazing wire was made into a preformed ring that sat on top of the joint. The part was successfully brazed in about 1 minute.
UltraFlex 5 kW induction heating system was used under a PID loop to make sure that the power will drop as we were approaching the desired temperature to ensure we would not melt any of the aluminum.
Read more about other induction brazing applications here.
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Reference Info: Application Note 3463-6556