Induction Heating Copper and Nickel for Bending
A specially designed multiple-turn helical coil was used to provide heat to the parts. Initial tests were conducted to optimize the power delivered to the part and to understand the heating patterns achieved.
Induction Heating a Tube to Heat Gases
To heat an Inconel tube with a custom-designed multiple-turn helical coil for a gas heating application
Heating Copper Parts for a Burn-Off Application
To heat copper parts, which are battery lugs, for a burn-off application.
Preheating Steel Tubes Prior to Bonding
To heat steels tubes for a bonding application; the end product is a bushing for large trucks. Induction would replace an oven for this client.
Heating a Copper Wire for Coating Removal
A custom-designed multiple turn helical coil was built to generate the required heating for this coating removal application.
Heating a Steel Pan to Evaporate Water
A multiple turn pancake coil was designed to provide heat to the base of the steel pan. Initial tests were conducted to optimize the power delivered to the part and to understand the heating patterns
Brazing a Copper Tube and Brass Fitting Assembly
To heat a customer supplied copper tube and brass fitting assembly for a brazing application; the customer, a manufacturer of heat exchangers, had been manually brazing the assemblies.
Brazing Steel Assemblies (hydraulics)
A custom-designed single position multiple-turn oval split helical coil was built to generate the required heating for this brazing application.
Heating Stainless Steel Assemblies to Remove Glass
A custom-designed single position multiple-turn helical coil was built to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.
Brazing an Aluminum Tube Assembly
A custom-designed single position multiple-turn pancake coil was built to generate the required heating for this brazing application. Initial tests were conducted to optimize power delivery to the assembly
Heating Steel Assemblies for Sealing
A single position multiple-turn pancake shaped coil was built to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.
Heating a Flanged Part Before Welding
A custom-designed single position multiple-turn oval coil was built to generate the required heating for the preheating application. Initially, a helical coil design was used which did heat the part faster, but the pattern wasn’t uniform.
Brazing a Carbide and Steel Assembly
A custom-designed single position multiple-turn helical coil was built to generate the required heating for this brazing application. Initial tests were conducted to optimize power delivery.
Brazing Copper Tubes for a Solar Industry Application
A custom-designed single position multiple-turn split-helical coil was built to generate the required heating for this brazing application.
Heating a Steel Susceptor for Glass Cutting
A custom-designed single position multiple-turn helical coil was built to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.
Brazing FishhooksA custom designed single position multiple-turn helical coil was built to generate the required heating for the application.
Heating Non-Magnetic Steel Tubing
To heat non-magnetic steel tubing for an application in the energy storage market.
Brazing Copper BussbarsA custom-designed single position multiple-turn helical coil was built to generate the required heating for the application.
Heating Surgical Tools for Coating Burn Off
To heat surgical tools to burn-off the nylon coating; the client had been using a torch for this application. Within seconds of the power being turned on, the coating on the tool began to smoke and soon started to bubble.
Heating Steel Cutting Tools for Carbide Removal
Using induction to heat magnetic steel cutting tools for removal of carbide cutting tips. Induction efficiently and precisely heats the client's part in a controlled manner delivering only the required heat.
Brazing a Copper Tube & Brass Fitting
A custom-designed single position multiple-turn U-shape coil was built to generate the required heating for this brazing application.
Heating Steel Coated Copper Wire
In static tests, it was observed that it took 2.5 seconds to heat an 11” (279 mm) length of sample wire to target temperature.
Brazing Copper and Brass Valves
To braze various copper and brass assemblies for a valve manufacturer; they are looking to replace their torch heating process with induction
Brazing Steel Fittings & Tubes (Hydraulics)
Braze steel fittings and tubes in an atmosphere to make hydraulic fittings within a targeted heating time of under 150 seconds.
Heating Steel Shafts for Forming (Medical Tools)
A custom-designed single position multiple-turn helical coil was built to generate the required heating for this application.
Heating Graphite DiscsA custom-designed single position multiple-turn pancake coil was built to generate the required heating for this application.
Brazing Both Ends of a Steel Assembly
The client wanted to braze both ends of the part concurrently within their time requirements. Induction met the client’s time requirements and is often faster than other heating methods. With induction there is no open flame and with induction’s instant on/off capabilities, it introduces less heat into the work environment.
Heating Steel Pipe for a Casting System
The client wants to replace their resistive steel pipe heating process; it takes 15 minutes to reach the desired temperature.
Brazing Copper and Brass Fittings (Flange)
How to braze copper tubes and a steel plate for a brazing application; while this is a new process for the client, they also tested the process with a torch
Steel Nozzle Assembly (Aerospace)
Where you can struggle with repeatability with an oven and torch, induction brazing is a more repeatable process. With induction heating, there is no open flame and the benefit of instant on/off capabilities. This introduces less heat into the work environment.
Preheating Parts for WeldingInduction dramatically reduced the heating time they saw with torch heating as it dropped from 20 minutes to 3 minutes
Brazing Brass and Copper Nozzles
To braze copper and brass samples for an application in the aerospace industry, induction heating was used in place of a previously used torch. Induction brazing allows more consistent, higher quality parts.du
Heating Steel Knives; Food Processing
To rapidly heat steel knives on the line of a food processing facility, improving efficiency; the client had been using a different heating method.
Brazing a Steel Part for the Aerospace Industry
A custom-designed multiple-turn helical coil was built to generate the required heating for a steel cable for the aerospace industry. Induction brazing was used to heat a steel part for a brazing application.
Drying Steel Rings with Induction Heating
To heat streel rings for a drying application; the client was using hot air but it wasn’t completely drying the rings
Brazing, De-brazing Carbide, Steel Plates
A custom-designed special multiple-turn helical coil was built to generate the required heating to heat a carbide and steel plate assembly for a brazing and de-brazing application in the oil and gas industry.
Preheating Rod Assemblies for Welding
The client had been using torches for preheating. However, due to process improvements thanks to new automation in their facility, torch heating became too slow. This resulted in a backlog that kept them from maximizing their throughput.
Brazing Brass Assembly; Sink Manufacturer
To heat brass assemblies for a brazing application, the client, who manufactures sink products had been using a torch. Induction heating heated the assembly to temperature and better met the client’s time requirements.
Induction Preheating Steel Laminate Parts
The c-lams are inserts for an automotive industry application. In production the robotic pick-and-place will occur for plastic overmolding after heating by induction.
Brazing a Copper Tube and Steel Plate
In order to braze copper, a custom-designed single position multiple-turn helical coil was built to generate the required heating for the tube-to-plate brazing application. Initial tests were conducted to optimize the power delivered to the part. Repeatability was a top priority for this client.
Heating Busbars for Coating Release
Induction’s precision heating enables the part to heat to the exact targeted temperature, which prevented melting of the tin-coated copper part
Heating Automotive Battery Cables for Adhesive Melting
Temperature indicating paint was applied to the parts, and it took 10 seconds to heat the various styles of the part to the targeted temperature. This testing achieved the client's time and quality objectives.
Brazing a Nickel Pin and a Nickel Wire
A client had been using flame heating to braze a nickel pin and a braided nickel wire. The end-product is a heater assembly. Using induction improved joint quality compared to using flame heating.
Heating Lighting Tubes for Getter Firing
The getter firing application was complete within just 10 seconds. Induction delivers the same result time after time, making it ideal for their high-volume manufacturing process
Brazing a Carbide Tip and Magnetic Steel Tube
To braze carbide inserts into magnetic steel tubes, an inconsistent torch process was replaced with induction brazing equipment. In this application, quality rather than speed was the top priority.b
Heating Wires and Strips for Coating Removal
The polymer coating on the aluminum strip behaved differently when heated. Visually, the coating turned brown and bubbly when the aluminum strip was heated
Brazing a Steel and Carbide Assembly
To braze a steel and carbide assembly to create a mining bit for the oil and gas industry, this client replaced their torch process with the repeatable and flameless induction brazing technique.
Braze a Copper Tube and Brass Fitting (fuel containment)
How to braze copper using a custom-designed single position multi-turn helical coil built to generate the required heating for the copper brazing application.
Heating an Aluminum Tube for Bending
Induction does not present an open flame into the work environment like a torch, resulting in a safer working environment
Brazing a Copper Strip Assembly
The client requested a system that would meet their time objectives which the EKOHEAT easily did, boosting the client's throughput.
Heat a Fixture for a Wire Heating Application
Heat a non-magnetic metal alloy shape-setting fixture for a Nitinol wire heating/shaping application.
Induction brazing a Steel Tube with External Wire Braid
The coil selected is not only capable of induction heating the steel 7/8/22 mm tube, but also a smaller tube that the client needs to heat.
Heating a Tube Prior to Swaging
With the process designed by Ambrell's applications engineers, the tubing heated to temperature within five seconds. This result met the client's objective
Brazing, De-Brazing Diamond Carbide Inserts
Heat steel cutting bits with diamond-carbide inserts for brazing and de-brazing; the end products are cutting tools
Preheating a titanium alloy wire prior to welding
With an EKOHEAT 10 kW power supply, the titanium alloy wire can be heated to 2732 °F (1500 °C) in three seconds. This testing configuration simulates using three EASYHEAT 10 kW power supplies in series.
Brazing a steel and carbide dental assembly
This configuratoin achieved the client's objective. The channel coil - specially designed by THE LAB at Ambrell- was critical to the application's success.
Brazing a brass tube and flange; torch replacement
Application engineers determined placing a turn that is targeted to the tube inside the part would optimize heating for this application. This heats the tube while the flange is being heated enabling both parts to achieve the required temperature concurrently.
Brazing a magnetic steel cutting tool with induction
Induction heating rapidly heats the steel parts to the required temperature, especially with the EKOHEAT's Auto Tap feature. The Ambrell Applications Lab used their expertise to create the right solution for the system and the system hardware.
Heating a cutting knife, improving cut
In this example, induction heating provides consistent, repeatable results, a safe, reliable source of heat, measurable & stable results and less production scrap
Preheating a magnetic steel die
The induction process required 10 minutes to heat to the required temperature; the client's resistance heater took more than ten minutes. Also there will no longer be a need to open the chamber to remove the heater.
Brazing a steel and copper strip to carbide
Induction heating of the steel took less than 30 seconds, is highly repeatable and there is no open flame, clear benefits over flame heating. it a safer method of heating than torch heating
Heating aluminum wire to create screens
Induction will double production due to more rapid heating than infrared lamps can offer; with induction 100 feet per minute can be run instead of 50 feet per minute with infrared
Induction brazing a rectangular steel part
Induction heating of the steel took 30 seconds (or less), which can't be matched when using a torch. This client was using an old induction system from another vendor, and the Ambrell system provided considerably faster heating
Heating rods for thread rolling to create fasteners
This is part of an automated line. The system was sized and the coil was designed to ensure 45 parts per minute can be heated to the temperature required for hot forming.
How to braze a copper tubeThe client had been using a torch, which took 50 seconds instead of 30; induction brazing the copper increased repeatability and in turn boosted part quality. Also, there is no open flame which makes it a safer method of heating than torch heating
Induction heating stainless steel inserts for an insertion application
Induction heating offers dramatically faster heating compared to ultrasonics which means dramatically increased production rates. Induction is highly repeatable and easy-to-integrate into manufacturing processes.
Copper block & carbide; contact assembly
Induction completed the carbide brazing process more rapidly than an oven, delivering heat exactly where it's needed, operating instant on/instant off
Hot forming a steel pipe with induction
A 2.5 inch steel pipe is heated by induction to the targeted temperature quickly with induction's repeatable process. EKOHEAT is easy to integrate into manufacturing processes and targets only the portion of the tube that requires bending while not heating the remainder of the tube.
Induction heating steel coupons and carbide cutters for brazing and de-brazing
The first coupon that was heated had a 16 mm (0.63) diameter cutter, so removal of the cutter was the objective. The part was coated in black flux and inserted into the coil...
Brazing aluminum adaptors to the end of aluminum tubes
To increase production, a multi-position coil was recommended so multiple parts could be heated while maintaining a cycle time of 55 seconds, delivering consistent joint quality, which a torch often doesn't deliver.
Induction heating a steel grenade for a disposing application
The grenade was then placed inside the coil and power was turned on. After just two seconds the painted indicated, meaning the part achieved 800 °F (427 °C).
Brazing a nickel sleeve to a copper mast
To heat a nickel sleeve and a copper mast for a brazing application to create a pitot tube for the aerospace industry
Tempering an audio speaker screen
The speaker screen was placed over the induction coil and the power was turned on. The screen heated to the desired temperature within just one second
Brazing a brass screw cap and a steel tube
Induction heating enables brazing the cap and tube to be completed at a rate of 15 seconds per part while delivering consistent joint quality in a safer environment which a torch often can't offer...
Brazing a stainless steel fitting to a stainless steel capillary tube
Induction enables consistent joint quality in about 35 seconds, which a torch often doesn't deliver; in this case this is the primary reason for switching to induction
Heating an aluminum-backed circuit board to reflow solder
Given the significantly faster heating time, induction improves throughput in this process and is a more efficient heating method than hot plate heating
Heating a Kovar tube for a glass sealing application
The client was using a torch, and operator error was slowing the heating. The repeatability of induction enables improved throughput while in this process it is a more efficient heating method than torch heating, also reducing scrap
Brazing a steel coupler and a steel wire
Induction heating enabled the brazing process to be completed within 30 seconds. The client was using a torch, and induction offers superior repeatability with no open flame and delivering heat only where it's required...
Heating a chromel grid for an oxidization application
Induction delivers a dramatic reduction in heating time, enabling a significant increase in production while providing a more energy-efficient heating method than furnace heating
Induction Pre-heating a steel transaxle tube for a welding application
Induction heating achieves an identical result consistently, and is a more efficient heating method, each of which are advantage over torch heating
Brazing brass tube and fitting assemblies
The brass tubes and fittings heated to required temperature far more quickly than with customer's torch method, resulting in improved part quality and introducing less heat into the production environment...
Pre-heating a steel plate and a carriage roller shaft with induction for a welding application
Induction heating achieves the client's targeted speed/production rate and opens up the possibility of preheating while welding
Brazing carbide tips to a steel cutter
The cutter was held in a vice and the coil was presented to heat the assembly. A ceramic rod was used to press the carbide tip onto steel cutter during brazing.
Heating fluid passing through an alumina tube
To heat an alumina tube to heat magnetic particles in order to heat fluid passing through the tube for an oil industry application
Brazing a copper tube assembly
The proposed system is capable of heating a wide variety of tube assemblies, is light enough to be used on a cart and is able to meet the client's time/productivity objectives
Heating the joint area of two lead plates for a butt welding application
The client was using a torch, which took five minutes; induction takes just one minute, which means an improved production rate and, unlike a torch, induction heating is precise and repeatable...
Brazing a brass tube assembly (valve manufacturing)
With the recommended coil configuration, the cycle time turned out to be 25% less than what the client was targeting, resulting in increased production efficiency; a good braze joint was formed, and induction's consistency and repeatability proved valuable
Induction heating cylinder liners for insertion into aluminum engine blocks
Temperature indicating paint was applied to the steel part for testing purposes. The part was then placed into the induction heating coil and the power was turned on. In just under 30 seconds, the part achieved temperature.
How to braze three copper tubes to create a four-way valve
Due to the use of a higher power system, speed expectations were exceeded and improved over the client's previous method, which was torch heating. A good copper braze joint was formed, and induction's consistency and repeatability proved valuable. Induction brazing doesn't employ an open flame, which results in a safer work environment
Heating stainless steel finned parts
Induction is a targeted, precise heating method with instant on/off, saving users energy and it is a flameless heating method, so it provides employees with a cooler, lower-risk working environment...
Brazing copper tubes to a brass manifold block
The proposed process met the client's time objective, and is faster than oven heating.
Heating a coated copper wire for a stripping application
The top 1 (25 mm) portion of the plastic coated wire was placed inside the helical coil and heating began. The top turn rapidly started to heat and the plastic melted after about 10 seconds of heating...
Brazing copper and brass valve assemblies (HVAC)
The copper tube (1/8/3.2mm) is inserted into the flared copper tube (1/4/6.4mm). Two braze rings are placed on the copper tubes and the power is applied....
Heating a copper end cap to temperature to melt wax
To heat a copper end cap to temperature for a wax reflow application; the end product is a temperature stat and the client is looking to cut their heating time in half...
Brazing steel drill bits (aerospace)
The client wanted to heat three parts concurrently, and this process allowed up to five parts to be heated concurrently...
Preheating copper barsTo preheat two copper bars to temperature within 30 seconds; the client is looking to replace a competitor's 5kW induction heating system that is delivering unsatisfactory results
Brazing steel flange and shaft assemblies (aerospace and automotive applications)
Induction brazing is a repeatable process that isn't as labor intensive as a flame often is. The process can heat the assembly rapidly and more energy-efficiently than a torch without the safety risks that come with an open flame
Brazing two fittings and a helical tube to create a mount
The client had been using a torch, and was dealing with inconsistent results that impacted part quality. Induction heats the assembly more quickly than the torch..
Heat steel plates of various thicknesses with induction on the same line
This in-line system enables the client to heat plates with significantly different thicknesses, while the feed-rate varies considerably based on the thickness of the part. Induction is the fastest method of heating steel plates to the required temperature
Brazing tubes and fittings for an air conditioning unit for the off-road market
Clients were using an oven, and because the whole part was being heated and essentially annealed, it created problems with the part. Induction only heats the braze area, and resolves that issue...
![Preheating a copper rod and connector [epoxy curing]](https://www.ambrell.com/hs-fs/hubfs/ambrell-images/Applications/Thumbs/heating_77.jpg?width=95&height=95&name=heating_77.jpg)
Preheating a copper rod and connector [epoxy curing]
Induction heated the part to temperature quickly in a far more efficient method than an oven, heating only the parts of the rod that required heating
Brazing a steel and brass immersion heating element
Induction results in faster heating than a torch with faster, multipart heating to increase output...
Heating a titanium bracelet; create the desired finish
Within 35 seconds the center band of the bracelet turned black. The client had been using a torch, but looked to induction due to speed, safety and repeatability...
Brazing an aluminum assembly for a bicycle manufacturing application
For this aluminum bicycle tube brazing application, induction heating delivers more repeatable and consistent results, while cutting client's heating time in half when compared to using a torch...
Preheating a titanium billet to temperature prior to rolling
Induction uniformly heats the large billet and the client's longer 15 foot billets quickly to 1800C.
Brazing a magnetic steel tube and steel mating assembly
Heating a 0.437 (11.1) in(mm) outside diameter magnetic steel tube and steel mating assembly to temperature for a brazing application to create an oil tube for the railroad industry...
Heating a nanoparticle solution to 40 °C
Heat a nanoparticle solution to get it to increase at least 40 °C for medical research/laboratory testing
![Brazing an aluminum manifold [air conditioning]](https://www.ambrell.com/hs-fs/hubfs/ambrell-images/Applications/Thumbs/brazing_74.jpg?width=95&height=95&name=brazing_74.jpg)
Brazing an aluminum manifold [air conditioning]
Precise, repeatable heating: The client wanted more precise and repeatable heating than a torch could deliver, which induction was able to achieve..
Stress relieving flat blanks of carbon steel to reduce wheel hardness
Induction rapidly heats the carbon steel to temperature, enabling a rate of 30 feet per minute, not only saving production time, but saving energy costs. With a modest footprint, induction is easily implemented into production processes such as this one...
Brazing a steel tube and fitting to create an automotive valve
Customer's client was unhappy with the results from MIG welding, which drove them to look at induction as an alternative process. Induction heating proved to be a fast, repeatable heating method for the application...
Heating an Inconel tube (incineration)
Induction offers uniform heating, which flame does not offer, is more efficient than flame and can rapidly melt the materials
Brazing a carbide ball to a spring to create a part that controls the armature position in a motor
To heat a tungsten carbide ball and steel rod that acts as a spring to 1300 °F (704 °C) within five seconds for a brazing application to create a part that governs the armature position in a motor...
Induction preheating a turbine blade (welding)
The end result is a preheating process that allows the part to move quickly to the welding step while meeting all quality requirements
Brazing a steel rod and sensor housing assembly
To heat a steel rod and housing to 1400 °F (760 °C) within 30 seconds for a brazing application to create an assembly for a sensor...
Heating a steel ball on a pin by induction for an insertion application
While the project is new, the customer wanted the steel part to be heated to temperature within four seconds, and that was easily achieved and exceeded with the EASYHEAT power supply
Heat a steel block with a cutout for carbide for a brazing application
Induction delivers improved quality and repeatability; client was using a torch and induction offered more precise, repeatable heating. In addition, this allowed the client to achieve the targeted heating time of 60 seconds, faster than what the torch could deliver...
Induction preheating steel rods for a welding application
Induction heating does a superior job penetrating the pin when compared to a torch, which is critical to preheating for welding and enables fast heating which can boost production compared to torch heating
Brazing a copper elbow tube assembly
In this copper brazing process, induction offers more precise, repeatable heating than current flame process...
Induction preheating a steel automotive transaxle (welding)
The steel axle was painted with temperature indicating paint and a thermocouple was attached to the part.
Brazing copper tubing and brass fittings for aerospace parts
Induction heating achieves superior process repeatability when compared to a brazing torch and a more predictable aerospace parts which enhances quality..
Heat a block of Haynes nickel alloy to test the crack growth rate
Testing was conducted to optimize the power delivered to the part. The coil was designed to minimize the voltage potential over the length of the part.
Brazing a steel tube and fitting assembly
Induction heating is used to braze a steel connector onto a steel tube to create a hydraulic component. ...
Induction preheating a steel plate for forging
The induction heating process achieved a production rate of 100 steel parts per hour, while a gas furnace produced 83 parts per hour; the process is repeatable and can be integrated into a production process
Brazing stainless steel medical tool parts into a coupling
Induction heating is used to achieve client's goal to braze both stainless steel parts as quickly as possible with maximum repeatability...
Brazing steel tube fittingsA tube assembly is heated to the desired braze temperature in 20-25 seconds, which achieves the client's targeted cycle time of less than 30 seconds...
Brazing a magnetic steel rotor assembly
Induction is proposed to replace a hand-operated flame process requiring operator training and expertise. Induction heating delivers a precise, repeatable and reliable process. Improved joint quality is coupled with simplified operation...
Induction Heating Tool-Steel Circular Dies to 400C in 10 minutes
Induction heating delivers heat directly into the steel part, saving energy and time, can be easily integrated with a press, presents a greatly reduced footprint compared with oven, batch, carts
Brazing carbide insert to steel pipe gripper chuck
Induction heating is proposed to braze carbide inserts into steel blocks in the assembly of pipe gripper chuck. To replace a hand/flame process, delivering significant reduction in per-part cycles...
Hardening steel pipe segments (sleeves)
Disappointed with low quality levels in a previously outsourced process, the customer uses induction to bring the heat treatment and the control of the end-product quality in-house.
Brazing a copper pipe assembly seam
The customer is seam brazing copper pipes together. They will reduce the brazing of the seam down to 15-30 seconds.This customer is currently using a torch, but is not getting uniform quality
Heating a steel wire for tempering
Induction heating delivers heat directly into the wire, saving energy and time, easy integration into production line, improving throughput, precise control of heat and even distribution of heat within the wire
Brazing a pressure switch base assembly
Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating precise and controllable heat
Preheating aluminum flangesInduction heating delivers higher quality end product vs. using an open flame convection furnace. Ovens are sensitive to ambient temperature and humidity variations and tend to produce uneven results
Brazing brass and steel for valves and end plugs
The customer is currently using a torch to complete the braze joints. They wish to improve repeatability for a better process.
Desoldering Customer Assemblies with Induction Heating
To heat customer assemblies for a desoldering application. The client had been outsourcing this task, but wanted to see if it would be viable to bring the process in house.
Heating a 4 Tubular Carbon Susceptor to 5400 °F (3000 °C)
A tubular carbon susceptor is held within an atmospherecontrolled quartz chamber. Induction is used to heat the susceptor
Brazing temperature sensor assemblies
A five-turn two-position helical coil is used for this brazing application. Each coil acts individually and the coils are not designed to heat simultaneously...
Soldering Brass and Copper Components
A solder wire preform was placed on the part to allow for repeatable placement of solder in every joint. Four top or four bottom joints will be heated at one time within 2-3 minutes for the soldering application.
Pre-heating aluminum wheels prior to spray painting
This spray painting application requires pre-heating the material. Additionally, there is a requirement that the material must not cool below a certain target temperature prior to the spray.
Heating a Copper Assembly for Soldering
To heat a glass feed-through inside a copper block for a soldering application, one side at a time. This was a new application/process for the client.
Heat an Inconel tube for a swaging application
A need to increase volume and quality of parts production led to the choice of an induction process over flame. Handling is minimized and continuity is assured with the precision delivery of heating only where required.
Brazing Copper Tubes to a Braided Stainless Steel Hose
Customer is currently using flame and a highly paid operator to complete this application. With an induction system, the customer can save approximately $20,000/year in operator cost alone, not factoring in any energy savings.
Soldering Ferrule and Module Assembly
To heat ferrule and module assemblies for a soldering application in the fiber optics industry.
Heating iron oxide (Fe3O4) nanoparticles in an aqueous solution for research
An eight turn helical coil is used to heat the vials. 0.0625 thick insulation is wrapped around the vial and the vial is placed in the coil. The optical temperature probe is inserted into the vial with the base of the probe located in the middle of the coil turns.
Brazing two aluminum pipes to an aluminum evaporator core
The customer is replacing a flame process which can burn away the thin flange at the joint area and create scrap parts. By switching to induction for this application the customer is decreasing their scrap parts and also increasing their quality and production rate...
Soldering Co-axial Wire to a Metal Frame
Given the small size of the part and the assembly's geometry, a graphite cylinder was required as a susceptor.
Heating a pin assembly to cut holes in a rubberized material
Induction heating provides precise and consistent application of heat, consistent and repeatable results, hands-free heating that involves no operator skill for manufacturing
Brazing brass bellow assemblies for pneumatic regulators
Customer is replacing flame with induction to braze/solder these parts. While they are not looking to increase their production, they are looking for a repeatable and reliable process...
Heating a Kovar Ferrule for Glass Soldering
The solder formed a relatively uniform domed seal around the fiber despite the asymmetry of the open C coil. It took under 10 seconds to heat the part to soldering temperature
Preheating a molybdenum anode for stress relief
A four turn helical pancake coil is used to heat the anode. The area on the anode to be preheated is the weld between the tube and flange.
Brazing a stainless steel shaft to a carbide for a digger used in mining
A three turn helical coil is used to braze the carbide to the shaft. The steel shaft is fluxed and the braze shim placed on top. The carbide tip is fluxed and placed on top of the shim, lining up the countersunk hole in the carbide. The hole is not fluxed because the flux outgases and causes the carbide to build up pressure and attempt to repel from the shaft...
Soldering Four Fusible Copper Strips
Soldering with Induction takes under 10 seconds to heat four copper strips concurrently, resulting in a boost in throughput for the client. Induction is a highly repeatable process that heats just the area of the copper strip that requires it
Heating a steel chain for tempering
A twenty turn helical coil is used to heat the chain. The chain is fed through the coil at a rate of 1 meter per minute to reach the desired 1760 °F (960 °C) for the tempering process.
Brazing a small gas delivery assembly used to manufacture needles
This is a new part for the customer and they are developing the manufacturing process for it. The customer is interested in using induction heat for their process because they are looking for finished parts which are clean and not contaminated by any flux material. By using induction to braze the part and by doing the braze under a hydrogen atmosphere, the customer can produce brazed parts with no oxidation...
Soldering a pair of magnetic steel pins
Soldering with induction required under 10 seconds and is a highly repeatable process; the customer can expect the same result every time with only the portion of the part requiring heating being heated.
Heating top of aluminum oxygen tank for end forming
Through heating the top 2 (50.8mm) of aluminum oxygen tank to form a rounded end with a hole for oxygen valve
Brazing copper and steel tube combinations for refrigeration and air conditioning
Customer is currently using flame brazing in a large facility for this application and will gain safety benefits with induction such as no hazardous fumes or open flames...
Soldering a rivet onto a steel tank cap with induction heating
Soldering with induction proved faster than the client's previous heating torch process. It is also is a repeatable heating process, so the client gets superior results and is more energy efficient than torch heating.
Preheating steel bar stock to forge a hot formed u-bolt
A fifteen turn helical coil with ceramic insert is used to preheat the 15 (381 mm) section of steel bar stock.
Brazing a spray bar assembly used for powder coating
Customer is currently outsourcing this application. By bringing in-house they will save on inventory build-up, transportation cost, time-to-customer and money. Customer found Ambrell on the web and liked the idea that Ambrell's application lab can prove capability before purchasing.....
Heating a steel tie down assembly to loosen steel pin for rotation
Induction heating provides precise and accurate placement of heat without affecting surrounding areas, much faster process time, from hours to minutes, repeatable and consistent results and even distribution of heating
Brazing vertical copper bars to a copper slip ring for refurbishing large motor assemblies
A three-turn helical coil is used to heat the slip ring. Power is applied for 25 minutes to bring the ring up to brazing temperature. The slip ring is then held at temperature as the self locating 52 vertical bars are brazed into place...
Soldering copper tabs for stringing, tabbing solar panels
Induction's precision soldering ensures repeatable results and less damage to surrounding substrates while demonstrating reduced heat loss and lower energy usage...
Heating a carbon steel plate with a tin coating for flow-melting
A nine turn Dog Bone style coil is used for the flow-melting process. The tin coated carbon steel plate is placed in the coil for 1.34 seconds to uniformly reflow the tin coating.
Brazing copper cable and block assembly for generator repairs
A three-turn helical combination channel coil is used to heat the assembly. The assembly is placed in the coil with a thin ceramic paper placed between the coil and copper assembly...
Soldering electrical wire to a copper grounding
For this grounding lug soldering application, induction delivers consistent result is achieved each time and does not present a flame, so it helps create a safer, cooler working environment than other methods
Preheat steel for reformingInduction heating provides controllable heat pattern, ease of on site location use, safe, no open flames and even distribution of heating
Brazing aluminum electrical lug assembly
A five turn helical coil is used to braze the assembly. The parts are assembled and placed in the coil. Power is applied and a braze stick is used to braze the two parts in 25-30 seconds...
Soldering brass and steel radiator caps
The induction soldering process is completed within 15 seconds with consistent results without the use of flame, creating a safer, cooler working environment...
Preheating steel garden tools for press stamping
Induction heating provides hands-free heating that involves no operator skill for manufacturing, configurable heating profiles, faster process times and even distribution of heating
Brazing a stainless steel shaft to a carbide cone for a gripper
A three-turn helical coil is used to braze the carbide to the stainless steel shaft. A silver solder washer is placed over the post on the shaft, the carbide is placed on the washer and flux is applied...
![Soldering a copper tube to a brass valve [flow valve]](https://www.ambrell.com/hs-fs/hubfs/ambrell-images/Applications/Thumbs/soldering_46.jpg?width=95&height=95&name=soldering_46.jpg)
Soldering a copper tube to a brass valve [flow valve]
The heating process was completed within 12 seconds, faster than the client's gas torch and more reliably. Without flame, induction helps create a safer, cooler working environment.
Heating lead battery terminal for removal (recycling)
A single turn helical coil is used for this heating application. The lead terminal is placed inside the coil and is heated for 20 seconds.
Brazing a copper pivot assembly
A three-turn helical coil is used to heat the base of the assembly. The copper uprights and two braze shims are placed in the grooves in the base and black flux is applied...
![Soldering a copper wire, contactor assembly [motor]](https://www.ambrell.com/hs-fs/hubfs/ambrell-images/Applications/Thumbs/soldering_45.jpg?width=95&height=95&name=soldering_45.jpg)
Soldering a copper wire, contactor assembly [motor]
High intensity heat must be applied to the joint area for this application so that thermal conduction of the copper does not sink away the heat delivered from the induction process.
Heating a steel pipe to transport melted magnesium
Induction heating provides controllable and repeatable heat pattern that keeps material in liquid form, the technology is environmentally friendly, delivering even distribution of heating . The movable workhead can be located away from the power supply
Brazing brass faucet assemblyA two turn C shaped coil is used to braze the faucet assembly. The braze rings are placed at the joint, the parts assembled and fluxed...
Annealing Stainless Steel Braids
A specially designed multiple-turn helical coil was used to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part.
Brazing a steel piston valve assembly
A five turn pancake coil is used to braze the piston valve and steel plate. The assembly was heated for 10 minutes to flow the braze and join the two pieces...
Induction Annealing Springs for Stress Relief
Testing was successful, with a time-to-heat of 15 seconds. This client had been using an oven but was interested in changing to induction heating.
Heating magnetic iron oxide in water for hyperthermia application
Heating magnetic iron oxide (Fe2O3) in water for hyperthermia application to determine the curve of temperature vs. time during induction heating
Brazing a steel die into a wire drawing guide
A two-turn helical coil is used for brazing the assembly. Two different bonding agents are tested for the brazing application. The first bonding agent used is braze paste. The assembly is heated to 1382 °F (750 °C) and is brazed in 45 seconds....
Hermetic Sealing a Ferrule & Fiber Optic Cable
To heat a Kovar ferrule and fiber optic cable to 297°F within 10 seconds for a soldering application, to form a hermetic seal
Annealing Copper TubingA specially designed multi-turn helical coil was used to provide the required heat to the various copper tubes.
Heating graphite susceptor for glass reflow for X-ray tubes
A two turn helical coil is used for heating. Six graphite susceptors are placed in the nitrogen atmosphere with glass discs and a stainless steel holder.
Braze a thin walled tube to a steel cap in a hydrogen atmosphere
A single turn helical coil is used to heat the quartz tube and the tube assembly. The tube assembly is held in place inside the quartz tube by a copper fixture and hydrogen is fed into the quartz tube...
Soldering a fine copper wire to an electrical connector assembly
induction heating delivered a higher quality joint, is more energy efficient than the outdated system that the client was using.
Braze two positions on a stainless steel manifold simultaneously
A dual six turn split helical coil is used to simultaneously braze the manifold...
Soldering a steel canister for sealing
Current hand-soldering process results in uneven, non-uniform joints and requires long production times. Induction delivers uniform, quality joints by generating heat within the end-plate and reservoir walls.
Annealing a Metal PlateTo heat a metal plate for an annealing application; the customer wanted to improve the heating time they were seeing with an open flame/torch.
Heating a steel mold for rubber seal vulcanization
Induction heating provides repeatable and consistent heat, quicker process time, increased production and even distribution of heating
Braze a carbide tip to steel cutting tool
A split helical coil is used to heat the carbide & circular steel cutter evenly for the brazing application. The circular steel cutter is placed in a vise and the carbide and braze shim are placed onto the tooth...
Solder Fiber Optic Cable to Ferrule & Preform
Induction heating provides rapid localized heat only where needed, repeatable, consistent results with clean, controllable joints
Heating Three Steel Parts for a Bending Application
Clients are looking to upgrade cutting-tool torch brazing process with a fast, controllable and repeatable process.
Heating a steel steam trap for calibration testing
To heat a steel steam trap to 212°F (100°C) to release steam for calibration testing
Braze a mount lead to a ferrule in a PAR light bulb assembly for automobiles
A split helical coil heats 2-3 ferrules at a time. The ferrules are filled with flux and the mount leads are placed inside the ferrules...
Soldering a steel funnel to flex spout
Induction heating delivers non-contact energy-efficient heat without flame, resulting in repeatable and consistent results
Heat a compacted litz wire bundle for stripping
A three turn helical coil is used for the wire stripping process. The litz wire bundle is placed in the coil for 3 seconds to strip the lacquer 0.75 (19mm) from the end of the bundle. The wire bundle is then scraped with a metal brush to remove the burnt lacquer...
Hermetically sealing a fiber optic cable in a kovar ferrule
Induction heating provides instant start up time, requiring very little power resources, pin point accuracy, a clean source of heat which is easily integrated into existing automated systems
Annealing a Magnetic Steel Strip
A custom-designed single position multiple-turn helical coil was built to generate the required heating for this annealing application. Initial tests were conducted to optimize the power delivered to the part.
Heating threaded area of fastener
Induction heating is localized only to the threaded area, decreases production time with a flameless process and delivers even distribution of heating
Braze electrical contacts to brass and copper bus
A five turn split helical coil is used to heat the assembly. The parts are placed 90° to the coil between the top turn and second turn with braze shims and flux.
Soldering windows to time indicator housings
Soldering soda lime glass metal edged windows to steel time
Annealing Copper Wire Connectors
To anneal electrical crimp contacts of different dimensions. The client took advantage of THE LAB’s expertise to prove out their process in a way that met their time, quality and budgetary requirements.
Heating fastener blanks for thread rolling
Induction heating provides faster cycle times and extended tool life with preheat step, fands-free heating that involves no operator skill for manufacturing
Braze a diamond carbide tip onto band saw blade
A single turn helical coil is used for this brazing process. The saw blade and diamond carbide tip are placed in the coil...
Soldering a copper chip to a silver dipped brass RF attenuator
Induction heating provides repeatable consistent results in all three areas soldered at the same time, not individually. Faster process time, increased production and even distribution of heating
Annealing a Weld Seam with Induction
The client is building a system with induction. Induction achieved the client’s speed requirements and induction’s modest footprint works well within the system.With induction you can expect the same result every time.
Simultaneously heating six wire bundles to strip varnish
Induction heating provides hands-free heating that involves no operator skill for manufacturing. A multi-position coil provides simultaneous heating for quicker production times.
Braze a stainless steel braided hose to copper elbow for flexible hosing
A two turn helical coil is used to heat the braided hose assembly. Braze rings are placed...
Annealing a Weld Seam (Steel Assembly)
Annealing with induction required 45 seconds to heat the tube to the target temperature. This application met the client's objective
Soldering electrical wires onto three connector tabs on a three position wall socket plug
Customer is currently using a soldering iron & individually touching each soldering point which is producing inconsistent results and quality issues.
Braze an end plug on a stainless steel car grill
A three turn square shaped helical coil is used to heat the end of the grill. End plugs are inserted into the grill and the assembly is inserted into the coil for 30 seconds.
Anneal copper tubes; formed tubes & pipes
Induction annealing offers the same result every time, which makes it ideal for a high volume process such as this one. The previous oxidation issue forced them to polish the handles which added a step in their manufacturing process.
Soldering 3 copper spacers to circuit board simultaneously
Induction heating delivers precise, controlled application of heat in a repeatable, non-contact, clean heating process, enabling increased production capacity and improved energy efficiency
Heating a Nitinol spring assembly for shape setting
Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating along the wire. The wire is heat treated on the winding machine, eliminating a secondary process
Brazing joint on pressurized heater connectors
Brazing a joint between a copper lug and nickel plated copper pins on a pressurized heater connector.
Annealing a stainless steel handle
The client wants to anneal a stainless steel tube while avoiding oxidation. Induction annealing offers the same result every time, copper tubes of various geometries heated to temperature in a matter of seconds, which makes it ideal for a high volume process such as this one.
Research: Heating effects on stainless steel & Tantalum discs
A three turn helical coil is used to heat the discs to 1400 °F (760°C).
Brazing steel mold for golf ball dimple insert
Induction heating provides a no-flame process with reliable, repeatable, non contact and energy efficient heat in minimal time.
Annealing brass ammunition casings
The ammunition industry has been annealing with inefficient methods which require much floor space, lack consistency, create excess inventory carry costs, and don't permit in-process inspections. Brass annealing with induction ensures each and every case is quality annealed, reducing variation and damage typically found in mass annealing processes.
Heating solutions in vials for cancer research
A four turn helical coil is used to heat the vial for 30 second intervals for five minutes with a temperature reading taken at each interval.
Heat aluminum for brazing an automotive assembly
A multi turn pancake coil is used to heat the joint between the aluminum tubing and boss. The joint heats to temperature in 1.5 minutes and the braze ring melts forming a clean brazed joint.
Annealing stainless steel tubes
Annealing with induction heated the client's parts to the desired temperature in less than three seconds. Their previously-used gas oven required twice as much heating time as the induction heating process. Induction annealing is more energy-efficient and requires less space compared to a gas oven.
Press Fitting Steel SleevesInduction is typically a faster heating method for shrink fitting than alternatives like oven heating, offering instant on/instant off heating and
localized heating, making it an efficient option.
Preheating oil drilling shaft before welding
Induction pre-heating prevents shock to shaft which eliminates cracking in the welding phase. Hands-free heating that involves no operator skill for manufacturing.
Brazing stainless steel orthodontic begg brackets
A two turn oblong helical coil is designed to heat the steel brackets which are sandwiched between the two pieces of graphite.
Shrink Fitting Steel Pipe Assemblies
To shrink fit steel pipe assemblies; the end product is a glass processing system
Sintering copper powder to a stainless steel shaft
A four-turn helical coil is used to heat the assembly for five minutes. This provides slow, even heat for good penetration through the shell into the powder.
Brazing automotive tube assemblies
A four turn split helical coil is used to heat the steel assembly to 1400°F (760°C) for 85 seconds. The coil design allows for the steel fitting to expand away from the steel tube which allows braze to flow through the joint.
Shrink Fitting a Steel Part & Casing
A specially designed multiple turn internal helical coil was used to provide the heat to the various steel parts.
Bonding a Gasket to a Sombrero Nut
A multi-turn pancake coil is used to preheat the nut. It is then transported to the next station where it is pressed onto a gasket for bonding
Brazing carbide teeth to steel pipe jaw section
Induction heating provides hands-free heating that involves no operator skill for manufacturing, consistent, repeatable aesthetically pleasing brazes with even distribution of heating
Annealing stainless steel tubing
Looking to replace an inefficient oven process, a stainless steel tube is heated in just 30 seconds, improving efficiency for this application. A custom-designed single position multi-turn helical coil was built to generate the required heating for this induction annealing application
Soldering Electrical Flex Circuits
To heat multiple joints on flex circuit strips to 180-200°F within seven seconds for a soldering application.
Shrink Fitting Magnetic Steel Pistons
Using induction for shrink-fitting magnetic steel pistons onto a chrome shaft; the client was using an unreliable handheld induction system and wanted a higher quality induction shrink-fitting solution.
Heating a motor prior to adding an injection molded part
Induction heating enables quicker process times with increased production rates versus a gas-fired oven. Ovens require long heat-up and cool-down times
Braze a refrigeration tube coil assembly
Induction heating provides the ability to direct heat only to the required zone, coil geometry which allows for easy loading and unloading of finished parts and the ability of coil to be used with water bath process allows for stability of the o-ring
Soldering a Radio AntennaTo heat a coaxial antenna assembly to 600°F within 2 seconds for a soldering application. The goal to improve on an existing procedure with a soldering iron which required 10 to 15 seconds.
Shrink Fitting Hammer BitsShrink-fitting hammer bits with induction for the insertion of carbide buttons; the end product is a drilling tool for the oil and gas industry.
Induction Bonding Metal to Plastic for Dental Tools
To prepare for induction bonding, the plastic handle was slid onto the picks or mirror and placed inside the induction heating coil and heated
Brazing stainless steel tree injector
Induction heating provides even distribution of heating, even flow of braze alloy for an aesthetically pleasing bond and system flexibility allows for the same unit to be used for two different applications which is a cost saving.
Annealing a copper wire connector (crimp)
The client wanted to be able to anneal parts of various sizes, which was achieved with a concentrator coil. Induction annealing is a new process for the client, and Ambrell's lab expertise proved very valuable when creating the process...
Soldering Solar Flex CircuitsHeat multiple joints on solar flex circuit strips to 500°F (260°C) within ten seconds for a soldering application.
Shrink Fitting a Magnetic Steel Gear
Induction shrink-fitting with EASYHEAT takes 45 minutes to heat the sample to the required temperature. The current oven process takes over two hours.
Induction Bonding Steel Cannulas
For each size cannula, the power delivered to the part was optimized to create a bond between the cannula and its bushing, without discoloring the steel of the cannula or causing the bushing to become opaque
Bulk heating a steel part prior to application of rubber molding
To preheat two irregularly shaped steel castings to be molded and bonded with synthetic rubber
Soldering three fuse caps simultaneously
Soldering three fuse caps simultaneously to reflow lead free solder and make a joint between the fuse cap and fuse wire guide
Induction Bonding Aluminum & Carbon Fiber Coupons
To enable the process of bonding with induction, three custom-designed single position multiple-turn coils were built to generate the required heating for this application (helical, pancake and u-shaped coils).
Heat a braided cable prior to cutting
To preheat two irregularly shaped steel castings to be molded and bonded with synthetic rubber
Braze four copper bus bars together
A three-turn helical coil is used to heat the assembly. Three braze shim preforms are placed between the plates and white flux is applied to the assembly
Annealing steel wire for a medical application
Induction annealing achieved the targeted steel wire temperature within three seconds. Ambrell performed a free laboratory test, designed a cost efficient, in-house process and connected them with an automation partner to maximize productivity. The client now has better control over their end product.
Soldering three brass connectors in a solar panel junction box assembly
Solder three brass connectors one at a time in a solar panel junction box without affecting the components in the junction box
Bonding Steel Wire; Rubber Molding
To heat steel wire embedded in rubber molding for a bonding application in the automotive industry
Hermetically sealing glass-enclosed resistors
Induction heating provides precise, consistent heat to very small parts resulting in repeatable, quality seals. By heating with medium frequency, arcing (which occurs at high frequencies) is avoided.
Bonding Steel Tubes to Plastic Tubes with Induction
Bonding with induction took just five seconds with our lowest power unit to deliver the bond just where it was needed.
Brazing a carbide and steel shank for a plug guage
Induction heating provides hands-free brazing which requires no special operator skills for manufacturing, precise, even heat is applied and is divided equally, between the shank and the carbide, providing an even flow of the braze alloy as the parts reach brazing temperatures.
Annealing stainless steel caps for a dental application
Our client had a requirement to anneal large quantities of work-hardened stainless steel crowns. Induction was suggested for its precise, controllable heating. Since oxidation is unacceptable in the finished dental product, induction heating is the appropriate choice for heating in an inert atmosphere.
Soldering a steel cover onto a nickel plated EMI filter
Soldering a nickel plated steel cover onto a nickel plated steel EMI filter housing without damaging the RF circuit
Shrink Fitting of BearingsA multi-turn helical coil delivers uniform heat to the entire range of the bearing sizes in the transverse mode.
Induction Tempering a SpringEnergy is applied directly to the springs only; surrounding air and fixturing are not heated.
Debonding Rubber Gaskets, End Rings
It took a modest amount of time to debond the rubber gasket from the metal end ring in this release/debonding induction application. Heat is delivered only where needed.
Braze steel O-ring Face Seal fittings to a steel tube
A four-turn 2.75 inch (7.0 cm) ID helical coil is used for heating both the steel tube and the ORFS sleeve or the ORFS male connector.
Annealing brass and bronze tubing prior to bending to form handrails
Employing brass annealing with induction to form tubes into handrails, a twelve-turn helical coil was used to heat an 8”x3” (20.3cm x 7.6cm) area above the end of the tubes. Each of the four tubes require a different heat cycle and time to reach the required temperature.
Shrink Fitting an Aluminum Tube
With an EASYHEAT 2 kW induction shrink-fitting system, the aluminum tube heated to the required temperature within 30 seconds. Shrink fitting then took place
Heat Staking Steel PartsTo heat steel inserts to be placed into a plastic frame. The end product is an automotive part.
Heating aluminium susceptor for powder expansion
Expand powder into solid form for use in crash helmets
Induction Bonding Adhesive to a Steel Washer (Automotive)
Bonding with induction heated a steel washer to the target temperature to enabling adhesive curing; it will be part of an automated process for an automotive industry application
Steel-carbide brazing cutting tool
The body shim and carbide are cleaned and braze flux as applied to the entire surface of the assembly. The parts are placed together in the induction coil.
Annealing a zinc wire prior to forming pellets for air rifles
A fourteen-turn coil is used to heat 3.9” (100mm) of zinc wire for this zinc wire application. The wire is placed in the coil for 5 seconds to reach the desired condition just prior to the forming process.
Soldering 2 electrical wires to copper buss bar
Induction heating delivers reduced solder time, even distribution of heating and improved joint-to-joint consistency
Shrink fitting an automotive aluminum motor housing
Induction shrink-fitting is fast, presents significant energy savings over an electric oven, requires a more modest footprint than an oven and can be easily integrated into an automated process
Metal-to-Plastic Insertion with a Brass Shaft
Multiple torches were required for this application previously, so the compact EASYHEAT minimized the required footprint for heating. With induction you can expect the same result every time, while variability is often observed with a torch
Heating steel liners (engine head)
Precise direct heat to disengage the aluminium quickly and cleanly. The aluminium casing is recycled and reused thereby reducing scrap and cutting costs.
Induction Bonding Plastic with a Steel Gasket (Automotive)
Induction bonding enables rapid heating, can easily be integrated into the client's manufacturing process due to modest space requirements and delivers a highly repeatable process.
Brazing carbide to steel for a surgical device
Compared to a stick-fed flame braze heating, induction heating provides consistently higher quality joints. This is critical for medical applications.
Annealing the end of a hydraulic motor shaft prior to machining
A three-turn helical coil is used to anneal the steel hydraulic motor shaft. The end of the motor shaft is placed in the coil and power is applied for 20 seconds to reach 1350 °F (732 °C) and turn the steel red hot before machining.
Soldering an LED assembly to an aluminum spotlight housing
A multi turn pancake coil is used to heat the bottom of the aluminum spotlight housing. The LED housing was not available so this application is done with temperature sensing paint to determine the feasibility
Inserting a Steel Bushing to an Aluminum Hub
The client currently uses an electric oven and the heating time is two hours, so at 60 seconds, the time savings with induction shrink-fitting is very significant
Metal-to-Plastic Insertion with a Steel Insert
The power was turned on for five seconds and the part was monitored during heating and for 15 seconds after.
Conveyor steel plate heatingHeat steel plates on conveyor system in order to cook Welsh cakes.
De-bonding a Magnetic Steel Paint Can Lid
The goal of the induction bonding process is to quickly and cleanly remove the can lid and to pour out paint to reformulate. Induction enabled rapid removal of the paint can lids.
Brazing a Plumbing Union in Tight Quarters
Induction provides a reliable braze joint obtained under limited-access conditions, energy is applied only to the joint; little energy is lost to surrounding parts and flame is not used; no bottled gasses required
Annealing aluminum fuel tank fill neck for bending
An eight-turn helical is used to heat the aluminum tube for annealing. To anneal the full length of the tube, the tube is placed in the coil and heated, and then the tube is bent while hot to prevent cracking.
Heating a Steel Pin for Fan Insertion
An EASYHEAT and its workhead require a minimal footprint, saving the client valuable floor space compared to heating alternatives
Soldering connector to wire harness
Induction heating provides reduced production cost, faster process time, hands-free heating that involves no operator skill for manufacturing
Forming a Large Steel TubeHeating an area around elliptical hole in steel tube prior to forming; the client had been using a torch for this application.
Heat steel pliers handle for bending
Precisely heating the desired zone avoids overheating of part. This provides higher quality vs. heating with a torch.
Bonding a Stainless Steel Sheet to a Soundproofing Mat
The part was assembled with the mat in contact with the stainless steel sheet. The part was set on non-conductive material, and placed inside the coil.
Brazing a Brass Trap Blockinduction heats only the material within the coil; no energy is wasted heating the surrounding materials and air; no flame or gasses required for heating
Annealing of stellite tips on saw blades
To anneal the affected zone of a saw blade after the stellite tips have been welded in place, a split four-turn helical coil is used to allow the blade to move evenly through the coil. Each tip of the blade is heated for 5 seconds as it passes through the coil to anneal the affected area.
Heating Steel Inserts for Metal-to-Plastic Insertion
It took 5 seconds with a 2 kW EASYHEAT to reach temperature, which melted the plastic for a solid bond without cracking the molded plastic.
Soldering two connectors simultaneously to gound plate
Induction heating provides non-contact heat, hands-free heating that involves no operator skill for manufacturing with even distribution of heating
Hot Heading Steel Wire: Create Screws
Preheating steel wire before hot heading to create a screw; they wanted to switch from cold heading to extend tool life.
Curing Oil Filters for Agricultural Equipment
To heat steel parts for a curing application; the end-product was an oil filter for agricultural equipment.
Brazing Faucet Components, Assemblies
Three helical coils are used separately to braze a range of provided parts. Parts are assembled with flux and a braze alloy and then heated.
Continuous annealing of copper wire
To anneal a copper wire used in electric motors, a twelve-turn helical coil is used with an inserted ceramic tube to isolate the copper wire from the coil and to allow the wire to flow smoothly through the coil. Power runs continuously to anneal at a rate of 16.4 yds (15m) per minute.
Heating four brass inserts prior to insertion into a plastic motor housing
Using induction heating, the parts came to the required temperature in just 15 seconds in a highly repeatable heating method and a coil plate could offer protection against operator movement/errors
Curing coatings; steel tube, aluminum block
The client's oven had a heating time of 20 minutes, so the time savings from a 90-second cycle are considerable. Additionally, induction is a repeatable process, unlike an oven and the induction system takes up less floor space than an oven.
Soldering fabric to kovar tip assembly
A three turn pancake coil is used to heat the tip of the cone to 300 °F (149 °C) in 2-3 seconds
Shrink Fitting A Gear to a Shaft
The customer was using a torch, which can lead to inconsistent part quality. Induction's precise heating means the client can count on consistent results in their process
Heating Cutting Tools for Forging
An infrared pyrometer was used to monitor the temperature of the part during the heating cycle. Two parts were tested.
Heat aluminum molds to release baked food products
Induction heating is safer than heating with a convection oven. Grease from the molds causes a fire hazard and waste gases in the oven.
De-Bonding Urethane From A Steel Insert (Doffer Pad)
A three-turn pancake style coil is used to de-bond urethane from the steel disc. The part is placed onto two 0.10 (2.5mm) thick ceramic rods on top of the coil and heated for 15 seconds...
Brazing Brass Fitting to Copper Tube
For larger copper tube assemblies, the same process is used, but the braze alloy is stick-fed to the joint to prevent the alloy from flowing out of the joint.
Annealing lip on cryogenic dewar
A two-turn helical coil is used to heat the lip on the cryogenic dewar. The dewar is placed in the coil and power is applied for 2 minutes to anneal the required 1 heat zone...
Heating stainless steel inserts for an insertion application
Induction offers dramatically faster heating when compared to ultrasonics; faster heating means there is the potential to dramatically increase production rates with a highly repeatable and easy-to integrate processes.
Soldering a kovar piece with glass to a copper base for a photon light source
Induction heating provides ability to use same equipment for both assembly and repair, hands-free heating that involves no operator skill for manufacturing, and uniform control of heat from part to part
Shrink Fitting an Aluminum Motor Housing
The customer was using a cold press, but it was creating part defects. This was resolved with induction heating: the process took just two minutes compared to 40 minutes and they were able to achieve their targeted production rate.
Curing Epoxy On A Laser Diode Assembly
To heat epoxy on a laser diode assembly to 250°F within 5 seconds for a curing application
Flattening/Bending Steel Tubes
Induction forging elevates the temperature much more rapidly than an oven, targeting the precise portion of the part that requires heating every time, presenting a significant advantage over an oven
Heat twelve steel tubes simultaneously
The coil is comprised of two (2) six-position helical coils connected together in parallel to reduce the voltage requirements on the power supply.
Debonding inserts for manifold
A four-turn two-position helical coil is used to debond the inserts from the plastic. The coil is placed against the manifold and power is applied to the two inserts for 15 seconds to soften the plastic...
Brazing Carbide Tips to a Meat Cutter
Due to the size of the induction coil, the process allows for precise placement of the carbides on the steel shanks
Anneal an oval cut-out on a stainless steel tube prior to extrusion
To anneal a ¼” area around an oval cutout on a stainless steel tube prior to extrusion, a single-turn helical coil is used on the 4 (101.6mm) diameter tubes and a two turn helical coil is used on the smaller diameters.
Heating brass inserts for metal-to-plastic insertion
Innovation: Ambrell's Applications Lab was able to solve a problem that a competitor couldn't solve, which is a key benefit when purchasing induction solutions from Ambrell
Soldering brass and copper (anesthetic medical equipment)
This process is completed in two steps that use a 3 turn helical coil. The first process is to solder the brass ring to the copper piece which takes 85 seconds...
Forming a Magnetic Steel PartInduction heating drove the part to forming temperature more rapidly than a torch. Induction heating targets the precise portion of the part that requires heating every time
Induction Melting iron powder; pucks for analysis
To heat a sample of iron powder for an induction melting application; the client manufactures metal powders
Induction Hardening Steel Blades
Optimum power is delivered to the steel blades to understand the heat pattern. The feasibility of the application is confirmed. The target temperature is achieved in less than 15 seconds.
Heat automotive seat springs to powder coat
Even heating of the spring before dipping provides uniform flow and provides consistent thickness of the nylon coating
Bonding a stainless steel needle to a plastic shank
A pancake/plate coil is used in this application. Ten assemblies are placed in the coil and power is applied for 1 second to melt the plastic to the stainless steel needle
Brazing Copper Fittings to Refrigeration Valve
With induction, energy is applied only to the zone to be heated heating of the joint/braze is uniform and repeatable
Annealing the end of steel wire on a woven wire mesh
To prepare a wire mesh for press brake bending, induction is used to heat 3” (76.2mm) from the end of the wire mesh 60” (1.52m) long. This provides a faster production process, higher efficiency, lower energy costs and a fast, controllable hands-free process that involves no operator skill.
Bonding plastic handles onto metal brooms
With a more reliable induction heating system, they will not have to worry about lost production due to power supply issues that come with an unreliable system
Soldering circuit board posts with lead or lead free solder preforms
Induction heating provides hands-free heating that involves no operator skill for manufacturing, lends itself well to automation, solder controlled by preforms, no excess left on board, good solder flow without over heating the board
Forging a magnetic steel rodTesting determined that the magnetic steel rod heated to required temperature within 1.5 seconds with an EASYHEAT LI induction heating system.
Shrink Fitting Stainless-Steel Sleeve & Shaft
The customer currently uses electric ovens that run 24 hours a day, 5 days per week and their primary concern is to save on the energy cost of heating the parts in the ovens.
Hardening surgical blades To quickly heat a steel surgical blade to 2000°F (1093°C) within 2 seconds so as to harden the blade edge.
Heating of steel rivet ends (turbines)
Heating steel rivets prior to head forming
Sealing a Nylon Shell for a fuel vapor Assembly
Filter modules are assembled on the fixture with ring gasket. Pressure is applied to the modules, modules are rotated and induction heating is started. After 10-12 seconds, heating is halted and the modules are removed from the fixture.
Annealing both ends of copper tubing for refrigeration
Induction heating applies heat to very specific areas, faster process time, increased production and high efficiency. In this application, both ends of a copper tube are heated to anneal them as soft as possible 1.5” (38.1mm) from each end, as well as retaining full hardness next to the anneals.
Metal-to-plastic insertion of threaded magnetic steel inserts
Outdated equipment and poor responsiveness drove this customer to a new vendor who could help them with new or improved processes for new or enhanced solutions
Curing plastisol adhesive; ends of filter assembly
Induction heating provides improved distribution of heat, much faster cure time than heat plates previously used, much faster production rate and hands-free heating that involves no operator skill for manufacturing
Soldering Brass end cap on heat exchanger
A dual four turn pancake coil is used to solder 2 brass caps per cycle. Liquid solder is squirted onto the end cap and is heated for 18 seconds at 302°F (150°C) to burn off the flux
Induction forging silver bars to create collectible coins
The client had been using an oven, and forging with induction can present some speed advantages. Unlike an oven, induction heating offers instant on/instant off heating
Shrinkfitting a steel mud pump liner
A twenty-turn helical coil is used to heat the chain. The chain is fed through the coil at a rate of 1 meter per minute to reach the desired 1760 °F (960 °C) for the tempering process...
Hardening Seat Belt PartsA four-turn helical concentrating coil is specially designed to deliver uniform heat to the steel seat belt retraction gear.
Pre-heating for a Hot-rolling Operation
Induction heating provides a much more rapid process compared to cold-rolling; the desired profile is achieved after a few seconds, compared with a few minutes.
Brazing a Cutting Tool Assembly
Two sets of parts are placed in the individual coils. Braze preforms are placed on the cone at the joint.
Annealing brass electrical contact for crimping
Induction annealing brass contacts provides hands-free heating that involves no operator skill, pinpoint accuracy and consistent results. To anneal a small area of an electrical contact for crimping, a one turn hairpin coil is used to heat the electrical contact to 1000ºF.
Induction Bonding an Arthroscopic Device
Induction is used to bond the device sheath to collet. Innovative coil design lifts production rate.
Curing a coating; both sides aluminum piston
A three turn channel coil 19 (48.26cm) long is used to anneal 4 pistons running though the coil with a distance of 6 (15.24cm) between centers.
Reflowing the solder of an area on a circuit board
An aluminum fixture is a large heat sink to the induction field. In order for solder alloy to wick and run the length of the overlap area, flux is applied to the solder location...
Hardening the teeth of a large saw blade
A torch isn't as precise as induction nor is it repeatable; induction heating is highly repeatable, uses less energy than a torch and offers instant on/off heating
Induction Melting of Ni based alloy samples
Induction melting provides hands-free heating, involves no operator skill required for manufacturing, even distribution of heating and fast, controllable temperature ramp
Shrink fit a steel gear onto a steel gear motor shaft
A four-turn helical internal coil is used to heat the gear bore. The coil is inserted into the gear bore and power is applied for 90 seconds to reach the required 400 °F (204 °C) and expand the gear bore...
Bonding Rubber Gaskets to a Steel Gas Intake Manifold
To bond rubber gaskets to the top and bottom of a steel gas tank assembly.
Oxidation of Graphite AnodesHeating carbon graphite anodes to destructively oxidize the parts to process embedded contaminants
Debonding rubber coating from a steel casted water valve
Induction heating provides minimal, if any, damage to parts process, is more environmentally-friendly without use of noxious chemicals and delivers even distribution of heating
Brazing carbide rotary file to high speed steel shanks
A multi-turn helical coil is used. The part is heated to determine the time required to reach the desired temperature and required heat pattern. I
Annealing a steel shaft for stress relief
Flameless induction heating allows processes - formerly done in batch furnaces - to be done in-line saving time and energy. No rotation of parts is needed.
Heat a steel shaft for metal-to-plastic insertion
Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating and localized application of energy limits temperature drift
Curing epoxy on aluminum copier roller assembly
A four turn helical pancake coil is used to heat the end of the copier roller assembly. The assembly is heated 90 seconds to cure the adhesive.
Soldering of satellite antennas
Induction heating delivers increased production rate due to speed of heating, higher quality vs. a soldering iron due to precision and repeatability and cost savings due to reduced scrap and higher quality production
Case hardening a steel fitting (machined parts manufacturer)
The coil design enabled the part to be raised into the heating coilfrom the bottom. The design was also made to ensure it will work well within the customer's current setup...
Heating a crucible for Melting plastic
A single-position 6-turn helical coil is used to generate the required heating for application. The crucible is heated in 70 seconds with the 5kW power supply.
Preheating steel rods for forging in a fastener manufacturing process
The client targeted an aggressive cycle time, achieve thanks to our process design and the efficiency of induction heating; fast heating means greater manufacturing throughput
shrink-fitting a carbide ring into a valve seat
A three turn helical coil is used to heat the steel valve seat. The steel valve seat is placed in the coil and heated for 50 seconds to enlarge the center hole & drop the carbide ring in for the shrink-fitting process.
Sealing an Aluminum Cap Seal on a Plastic Jug
To heat one aluminum cap seal on a plastic jug for a cap sealing application. The client is replacing past systems that no longer work for their process.
Heat the end of catalytic converter for weld testing
Heat the end of lorry catalytic converter exhaust system. The assembly must be held at target temperature for 200 hours, whilst the assembly is vibrated to test the weld strength
Debond rubber seal from steel oil seal ring
Induction heating provides highly accurate, fast, more efficient placement of heat, no effect to surrounding components
Brazing Diamond Drill InsertsInduction heating delivers reduced ring warping compared to furnace heating and decreased cycle time due to reduced ramp-up and cooldown times
Annealing bolt shaftsA three-turn helical coil is used to heat the shaft of the bolts for 10 to 12 seconds on the large bolts and 18 to 20 seconds on the smaller bolts using the same coil. This allows for pinpoint accuracy and repeatability, cycle after cycle.
Inserting brass bushing into plastic wire connector
A three turn helical coil is used to heat the brass bushing. The brass bushing is heated for 2 seconds and then placed on the wire connector & pressed into position.
Curing plastisol adhesive on an aluminum filter assembly
A four turn helical coil is used to cure the plastisol adhesive. One filter end cap is filled with adhesive, attached to the filter and heated 90 seconds to cure the adhesive.
Soldering electrical wires onto connector assemblies
Compared to using a manual soldering iron, induction heating precisely applies heat to for higher quality solder joints This is ideal for integrating with an automated system. By stick- feeding the solder more aesthetically pleasing parts are produced.
Surface hardening of steel screws
Induction heating enables precise application of heat, faster process time and production rates and the ability to be incorporated into existing production lines
Induction Melting silicon in graphite crucible for material testing
The customer is developing a university lab experiment to induction melt silicon and is still developing the process.
Induction forging rods of various materials and dimensions
Each of the rods were placed into the induction forging coil and heated. They achieved the targeted temperature in 30-40 seconds. The coil was designed for a 5 (127 mm) heat zone.
Shrink-fitting auto turbo charger impeller blades onto an aluminum shaft
Induction heating provides repeatable results, reduced cycle time, lower consumables cost and even distribution of heating
Bonding Foil to a Plastic Bottle
It was confirmed that the aluminum heated sufficiently to create a bond between the foil and the bottle, meeting the client’s objective.
Wire stripping (varnish removal)
An eight turn helical coil is used to generate the desired heat pattern. The coil has a 0.62 ID. An individual wire is inserted and heated to burn off the varnish for 5 seconds.
Sealing Aluminum Caps (Beverages)
Induction delivers the same result time after time, making it ideal for this high-volume manufacturing process. The space-efficient 45 kW EKOHEAT fits nicely into the client's floor plan.
Bonding plastic sleeve to stainless steel handle for food industry
Induction heating provides highly accurate, fast, more efficient placement of heat, no effect to surrounding components
Brazing a carbide shaft to steel tube
Induction heating provides even, precise heat. Precise directed heat is required for the solder braze to flow evenly around the part to assure a good joint.
Annealing Lock NutsA three-turn helical coil is used to heat the locknut to 2150°F for 5 seconds. Induction heating provides repeatable, rapid and accurate heating cycles making it ideal for in-line production processes
Heating magnetic steel for insertion into polypropylene for pallet manufacturing
Induction heating provides 'greener' manufacturing of pallets using reusable, recyclable materials, hands-free heating that involves minimal operator skill for manufacturing and even distribution of heating
Curing ink on aluminum bottle caps
A double channel coil is used for the ink drying application. Fifteen bottle caps are placed inside the coil and power is applied for 3 seconds to dry the ink.
Soldering Co-axial Wire Assemblies
A multi-turn helical coil is used and temperature-indicating paint is applied to the joint area. The wire assembly is placed over the induction heating coil, and RF power is applied.
Hardening teeth on a steel motorcycle gear
A single turn helical coil is used to heat the gear. The gear is placed on a spindle and rotated at 300-350 RPM's.
Induction Melting lead ingots to form battery posts and connectors
Induction Melting 30 lb(13.6 kg) & 60 lb(27.2 kg) lead ingots to form battery posts & connectors
Preheating a brass rod for forging
The client wanted to cut the cycle time it was getting from a torch in half, and the Ambrell induction process was able to meet that goal.
Shrink fitting aluminum pulley to insert inner bearing
A three turn helical coil is used to heat the aluminum pulley. The pulley is heated to 464 °F (240 °C) in 20 seconds to expand the inner diameter and then the inner bearing is inserted to form the completed part.
Heating Wire-impregnated Hose for Tube Forming
To reach a temperature of around 300 F requires a minimal amount of power.
Sealing a Plastic ContainerAn EASYHEAT and a workhead required a minimal footprint, saving the client floor space.
De-bonding Stainless Steel/Carbon Fiber Assembly
Induction heating process is more environmentally-friendly without the use of noxious chemicals
Brazing Brass Ship Fittings for Repair
The coil allows heating at the best possible efficiency which reduces the cycle time and the conducted heat along the brass tubes.
Anneal the end of metal stamp sets
Induction annealing heats the end of a metal stamp to mushroom instead of cracking/splitting when struck by a hammer. Two helical coils are used to heat the ends to the required temperature. Two part sizes can be run in each of the coils, using the same machine settings except for cycle time.
Inserting threaded brass parts into plastic thermostat housing
This application has three different coils for varying hole patterns. A three turn oblong coil is used to heat 2 brass inserts in close proximity.
Curing Alumium Car MoldingAutomotive manufacturers are constantly searching for cost-effective production technologies.
Soldering a copper tab on a speaker ring
With an efficient coil design induction heating easily reaches the desired reflow temperature in a very short amount of time.
Hardening steel screw threadsA five turn helical coil is used heat the screw threads. The screw is placed in the coil, heat is applied for 8 seconds to achieve a 2 long zone at the required hardness.
Induction Melting the end of a plastic tube to create a seal
A single turn coil encapsulated in custom blocks is used for sealing the tube. Two tubes are placed between the coil blocks and a 7lb (3.2kg) load is applied to the top of the coil.
Preheating a billet with induction for forging
The client needed to improve the cycle time of their gas furnace, and by preheating it prior to insertion into the furnace, time was saved and the client didn't have to invest in doubling the size of their furnace.
Wire stripping (heating varnish)
Removal of electrical varnish from copper strands of various diameters
Sealing an aluminum disk onto a plastic cap
Induction heating enabled the aluminum to seal to the plastic cap quickly without the cap being damaged. The customer desired a quick rate which would make in-sourcing the process worthwhile, and induction heating exceeded the targeted production rate thanks to its fast heating.
Metal to plastic bonding of beer kegs
A single-turn solenoid coil is placed around the assembled beer keg and heated for 35 seconds as the keg is rotated. Pressure is applied with a press on the top rim whilst the keg is rotating, forming a seal between the aluminium mesh and the two halves of the beer keg.
Brazing a Bourdon Tube Assembly
To braze a thin copper oval tube to a brass fitting at 1400 ° F and to cap the other end of the copper tube with a brass plate.
Annealing stainless steel bread cutting saw blades
Induction annealing improves blade quality, decreases scrap product and is easily incorporated into existing production lines. To anneal these stainless steel bread cutting saw blades, a three-turn helical induction heating coil is designed and developed for this application.
Inserting a piston stop with o-ring into an oil pump assembly
Induction heating provides increased production speed, simpler tooling for customer, hands-free heating that involves no operator skill for manufacturing
Curing Ceramic FiberA special steel tube and coil combination is used to build an induction heating oven to cure the fiber on a continuous basis. The ceramic fiber travels in an alumina tube inside a hot steel tube
Soldering a Stainless Steel Tube to Cylinder
Heat a.125 (3.175mm) diameter stainless steel tube to a 1 diameter cylinder 1 (25.4mm) tall for a soldering application
Hardening the end of steel hand-held marking stamps
To harden various size ends of hand held marking stamps. The area to be hardened is 3/4 (19mm) up the shank.
Crucible Melting a variety of materials in a nitrogen atmosphere
The crucible is heated using an induction coil with a four turn pancake at the base that extends upward into a three turn helical coil.
Preheating a brass assembly for forging blanks
The client was using a competitor's system, and it was heating the assembly at a slower rate. They needed to increase their production rate, which this solution was able to achieve.
shrink-fitting an assembled wrist pin into a connecting rod
Induction heating provides more accurate control of heat vs a flame burner, it heats only the knuckle, not the whole part, it prevents discoloring due to lower temperature used and increases productivity due to repeatability & ease of operation. A foot pedal & timer is used.
Heat setting of NitinolThe Ambrell system heats the fixture to the set point at the rates specified and the Nitinol wire is shaped as desired within 4 minutes, using less energy and time than traditional oven heating methods.
Heating pre-assembled plastic tube and cap for cap sealing application
Customer currently has Ambrell equipment and would like to increase their run rate.
Bonding Metal to Plastic for Dental Tools
Reliable bonds are produced when the diameters of the preassembled parts are consistent with little clearance before they are heated.
Annealing Tungsten RodsA multi-turn induction annealing coil is used to heat various rod diameters. An optical pyrometer is used to measure the temperature of the part inside the induction coil. Initial static tests are conducted, then dynamic tests are run to confirm the results of the static tests
Bonding of electric motor shaft to nylon face fan
Induction heating provides hands-free heating that involves no operator skill for manufacturing, only the metal shaft is heated so the motor is not affected, increased production due to rapid heating, decreased failure rate, originally used glue which ran into motor and caused failure and stronger bond
Curing Speaker Cone EpoxyInduction heating provides minimized coating defects, repeatable results and faster production times
Soldering Steel HousingA two-turn induction coil is used to deliver the heat energy into the steel housing. A small diameter solder wire is used to form a solder ring for the assembly process...
Hardening of Steel Cam Assembly
Hardening the cam outer surfaces with induction results in uniform heating for uniform results, one coil can be used for many geometries, consistent results from piece to piece
Induction Melting aluminum in a graphite crucible for casting
Induction melting provides hands-free heating that involves no operator skill for manufacturing, repeatable, dependable results, more efficient and cost effective then gas furnace, does not heat up the manufacturing area and increases production.
Preheating steel rods for forging in a fastener manufacturing process
The client targeted an aggressive cycle time, which Ambrell was able to achieve thanks to its process design and the efficiency of induction heating
shrink-fitting a cast iron rocker arm assemblies
A four-turn helical coil heats the ring at one end of the assembly. The coil is designed to concentrate the field towards the center of the assembly where the thermal mass is greatest.
Brazing Copper ‘T’ AssembliesTo heat copper ‘T’ assemblies to 1400(760) ºF(ºC) for brazing
Heating Copper Wire for Stripping
Removal of electrical varnish from copper strands of various diameters
Sealing aluminum foil cap to plastic bottle
Coil design can be incorporated to fit a wide range of production setups. Hands-free heating, involves no operator skill for manufacturing and directly heats only perimeter of foil.
Heating Steel parts for hot heading
Induction heating provides hands-free heating that involves no operator skill for manufacturing, direct application of the heat on the work piece with precision and consistency, even distribution of heating with low pressure and minimal residual part stress
Bonding Metal Housings to Plastic Holders for Lenses
Induction heating improves processing quality by delivering uniform heat to two parts at once using a single-turn peanut' coil. Localized heat enables easy alignment of optical components during final assembly
Band annealing on Titanium fasteners
Our bar-end annealing systems provide operating frequencies from 400 kHz for hot-heading of small diameter fasteners to 2 kHz for larger cross-section beams or bars. Systems can be incorporated with pick-and-place robotics to deliver a flameless process,with heating limited to a specific area.
Heating Four Inserts Simultaneously
The brass inserts are to be heated prior to insertion into a plastic automotive sub assembly
Curing the Inside Liner of Baby Food Bottle Tops
A three turn oval pancake coil is used to cure the inside liner of a baby food bottle cap. The bottle cap travels through the coil at 25 per second to cure 500 caps per minute.
Soldering Cellular Phone Antenna
Soldering two brass tubes measuring 3/4-inch and 1/4-inch together for use as cellular phone antennas. The lengths of tubes range from four (4) feet to twelve (12) feet, and must be soldered along the axial side.
Case Hardening of Armature Shaft
A five turn helical coil is used to heat the gear end of the shaft to 1700°F
Hermetic sealing: SS rods & glass preforms
Induction melting provides hands-free heating that involves no operator skill for manufacturing, amounts of glass are precisely controlled by the glass preforms and even flow of glass creates aesthetically pleasing bond.
Preheating for forging of steel pins
Fast, precise heating of the pin - 2 minutes and 36 seconds were saved on heating all of the rim's pins when compared to using a torch
Shrink fit a motor shaft and roller
Processing with induction heat saves power and time. The complete tube does not have to reach the desired temperature as it does when heating with an oven. Being able to selectively heat a zone allows for a much quicker transfer of heat.
Braze Copper Tube to Brass Fitting
To use induction heating to braze a copper tube to a brass fitting using a preform braze wire.
Sintering Powdered Metals for Satellite Positioning System
A four turn helical coil is used for the sintering process. Power is applied for thirty minutes under a nitrogen flooding
Getter Firing Lighting TubesThe process was completed within just 10 seconds, delivering the same result time after time, making it ideal for their high-volume manufacturing process
Cap Sealing 3.5 Lotion Container
Power is applied directly to the foil; no energy is wasted heating the cap or the surrounding air or parts.
Heating wire for hot headingInduction heating provides hands-free heating that involves no operator skill for manufacturing, elimination of springback effect, extended die life, better grain flow and microstructure with even distribution of heating
Preheating titanium rods for forging turbine blades
Forging with induction provides increased production rates, repeatable, reliable & consistent heat without flame and hands free heating that involves no operator skill for manufacturing
Bonding Solar Panel ShinglesTo heat the stainless steel substrate of a solar panel shingle in order to melt the polymer encapsulant, allowing two shingles to bond together with a 3 inch overlap.
Annealing Brazing WireInduction annealing provides higher productivity of 27' (8.2m) per minute, a reduction in surface oxidation & scaling with consistent, repeatable results. Four consecutive coils connected in parallel with a quartz tube lining,are used to heat the wire to 650ºF for annealing.
Brass InsertsHeating is to be accomplished within 5 seconds, and can be done in a helical coil since pick and place manufacturing is employed.
Bonding Rear View Mirror Brackets to Windshield Glass
A unique four-over-four double wound pancake coil is used for the bonding application.
Soldering Ice Machine Evaporator assemblies
To heat a section of 3/8 inch copper tubing along with a 90 degree elbow for soldering. The copper tubing is to be used in Ice Machine Evaporator Assemblies, and soldering takes place after the tubes have been placed within the assembly.
Hardening Cast Iron PulleysHeat cast iron pulleys to 1600°F(871.1°C) in order to achieve a hardness of 55 Rockwell C.
Remove plastic coating from steel tubes
Induction melting is the only feasible way to remove the plastic coating, leaving it in an unpolluted form for recycling. It is a faster process
Shrink-fitting a Camshaft Gear
Heating a camshaft gear with a bore size of 1.630 inch to shrink fit over a steel shaft that has a diameter of 1.632 inch. A temperature of 500F is required for the gear to expand 0.002 inch in order to slip over the shaft.
Brazing steel orthodontic parts
A four turn helical coil is used to heat parts. Brazing paste is applied to orthodontic parts with a syringe...
Brazing an Eyeglass Frame Assembly
Goal is to achieve quality braze joints on the nose bridge, brow bridge and nose piece.
Brazing Turbine Blades with Nickel
To heat an inconel turbine blade in a vacuum to 2000°F and hold temperature for five minutes for a nickel brazing application.
Heating Eight Steel Rods Simultaneously for a Molding Process
Heat eight steel rods simultaneously to 212°F (100°C) for a molding operation.
Getter firing in corners of rectangular vacuum display
By flashing or firing the getter, the residual gases are removed from the inside of the display.
Cap Sealing; Shampoo Container
A three-turn two-position helical coil is used to heat the aluminum foil in a tunnel style assembly. Product (containers) passes easily under the induction coil.
Pre-heating three rods for hot heading
Induction heating provides improved production rates with minimal defects, reduced need for post production tempering and heat treating and even distribution of heating
Heating stainless steel rod for hot forming
Induction heating provides for hands-free heating that involves no operator skill for manufacturing, improved production rates with minimal defects, low pressure and minimal residual part stress with even distribution of heating
Pre Heating Mold Release Push Rod For Forging
To heat the ends of steel rods to 1800°F using induction prior to a forging operation. Processing of the rods includes heating, pressing in a two part die to forge the push rod end, and a final induction heating in a channel coil to temper the rods and relieve the forging stresses.
Bonding Automotive Trim Vinyl Covering
Heating to 500°F is accomplished through the use of the unique coil; molding is continuously processed at a rate over 20 feet per minute.
Selectively Annealing Thread Ring Gauge Blocks
To selectively and uniformly anneal two sections of a thread ring gage block from the hole to the outside surface from a hardness of Rc 59-61 to Rc 45. Process goals include automation, production rate increase, and elimination of stress cracking resulting from flame heating.
Plastic Lawn ChairsTo heat internally threaded steel inserts to a temperature above 650F for insertion into plastic lawn chair assemblies.
Brassiere UnderwireTo heat the ends of 0.072-inch spring wire, spaced 1/2 inch apart, uniformly for the application of nylon powder on a 1inch length of the end.
Fuse thermoplastic catheter tubes
Heating of the mandrel is from the inside out providing a smooth finish on the outside of the assemblies.
Curing Adhesive on Steel Motor Shaft for Bonding
A complex two coil system, shield and stud systems used to provide proper axial alignments of the shaft & coil while allowing the fixture to be open for removal of the shaft.
Soldering Brass Bellows Assembly
To heat a brass bellows and end cap assembly to 450F for soldering within 20 seconds. Presently, a soldering iron is used to produce the joint between the bellows and cap.
Hardening Stainless Steel Surgical Knife Blades
A two turn helical coil with an internal quartz tube designed to scan the length of the blade is used to heat the blade to 1850°F (1010°C) to achieve the desired hardness.
Releasing a Lens Grinding Fixture Bond
The bonded assembly is placed (glass up) within a helical coil which circles the bonding slug. Induction heats the material to the melting point in 5-7 seconds.
shrink-fitting a Fuel Pump Housing and Inserts
To heat an aluminum fuel pump housing measuring 8 x 45 x 3.5 inch to 375F, allowing steel parts to be inserted.
Induction Melting Glass for Fiber Drawing
To heat a metal susceptor vessel to 2200°F within 25 minutes with induction for a fiberglass melting application
Brazing steel dental tools To heat a steel tip and shank assembly to 1300°F (704°C) within 3 seconds for brazing with induction heating instead of torch brazing.
Brazing Copper J Tube into Fittings
To braze a copper tube ( 3/8 in OD by 2-4 in long) into a 3/8 in fitting in less than 10 seconds.
Pre-heating a Truck Axle Seam for Welding
To pre-heat the seam of a truck axle to over 300°F within 15 seconds for a welding application and maintain temperature within the welding zone
Heating an Engine Valve Head for Stress Testing
To heat the face of an engine valve head to 900°F and maintain the temperature for an extended time, high temperature stress test.
Repair of Glass Lined TankTo heat selected areas of a glass lined steel tank to 16000 F in order to perform repairs of cracks and chips.
Stainless Steel HousingTo heat a stainless steel housing to 18750 F in order to fuse a piece of R6 glass to the inside of the housing.
Brazing Oil Suction Assembly with Copper Ring
To heat an oil suction assembly (steel tubing and filter cap) to 1,850°F (1010°C) within 15 seconds for a brazing application.
Brazing Copper Tube Assemblies
To heat a copper tube assembly in an inert atmosphere to 1450°F within 45 seconds for brazing without flux or acid wash clean-up.
Bonding a plastic handle to a surgical knife
Bonding handle of a stainless steel surgical knife into a plastic handle for very small areas within precise production tolerances
Pre-heating a Titanium Rod for Hot Forming
A specially designed thirteen-turn helical induction coil is used to heat the titanium rod to 1700ºF (926.7°C).
Heating a Titanium Blade to Melt & Drain the Wax
Heat a titanium blade to 500°F (200°C) to melt and drain the wax from inside the blade.
Brazing Hydraulic Hose Assemblies
To heat a steel hydraulic hose fitting in an inert atmosphere to 2200°F within 7 seconds for brazing without any carbon buildup.
Heating turbine engine fan blades for welding
To uniformly heat jet engine turbine fan blades to 1800°F (982.2ºC) within five minutes for a welding application
Heating Inconel Billets for Forging
A four-turn helical coil is used to deliver uniform heat to the inconel billets. Both size billets heat to 2050°F (1121.1ºC) within 12 seconds.
Brazing Stainless Steel Conduit to a Ferrule and Elbow Assembly
To heat a stainless steel conduit, ferrule and elbow assembly to 1400°F (760°C) within 20 seconds for brazing.
Soldering Steel Connectors to a Brass Block
Heat an assembly of small, gold-plated steel connectors to a brass block, heating to specific regions of part
Shrink Fitting Cam Shaft Gears
To heat aluminum and steel camshaft gears to over 500°F within 4 minutes for a shrink fitting application.
Heating Aluminum Auto Trim for Adhesive Curing
To heat various sizes of aluminum auto trim to 500°F (260°C) at a rate of 30 ft. (9.1m) per minute for curing an adhesive.
Inserting Steel Studs into a Plastic Tail Light
To heat threaded steel studs for insertion into a plastic tail-light assembly at 450°F.
De-Carburizing Jet Engine Fuel Nozzle
Heat a jet engine fuel nozzle to 1400°F (760°C) in order to decarburize it.
Getter Firing Light BulbsThe 2.5 second firing cycle allows for the coil to be move around the part and away within the indexing time of the turnstile table.
Pre-heating single rod for hot heading
A seven turn helical coil is used to heat the rod. The rod is placed inside the coil and power is applied for two seconds providing enough heat to penetrate the inner core
Stainless Steel 'J' TapeInduction heating provides for hands-free heating that involves no operator skill for manufacturing, improved production rates with minimal defects, low pressure and minimal residual part stress with even distribution of heating
Pre Heating Steel For Forging Horse Shoes
Induction forging provides for hands-free heating that involves no operator skill for manufacturing, improved production rates with minimal defects, low pressure and minimal residual part stress with even distribution of heating
Press-Bonding Metal Clips Into Sealers
To heat metal clips and press-bond them into rubber seals. The metal needs to be heated to 250°F to 350°F with a cycle time not exceeding 3 seconds
Achieving Uniform Hardness on Saw Blades
Induction annealing is used to draw-back steel saw blades to a desired Rockwell hardness at a rate of 60 inches per minute. Resulting mean hardness of 50.3 Rc is measured for fifteen saw teeth on a Wilson Superficial Hardness Tester, fulfilling the ultimate goal established by the customer.
Heating Catheter Tipping DieTo heat an aluminum catheter tipping die to above 285F within 2 to 5 seconds for the forming of catheter material.
Curing Measuring Tape PaintThe Ambrell 20kW output solid state induction power supply along with a unique 30 inch long multi turn helical coil was found to produce the following results.
Soldering Brass Slip RingTo heat 1.75, 3 and 6 inch diameter brass slip rings and a sheathed copper wire assembly to 360F for soldering within three (3) to six (6) seconds. Currently production is accomplished by using a soldering iron and stick feeding rosin-cored solder...
Hardening Bed Knife Blade for Reel Type Lawn Mowers
The hardness desired is between 45 to 55 Rockwell C, and should be measured 0.062in (1.6mm) from the cutting edge.
Induction Melting of Ticonium and Nobilium ingots
Due to the small size of the ingots, RF induction melting was required to efficiently couple to the samples in order to provide the necessary power to initiate melting.
Shrink fit a carbon graphite ring insert into an outer steel band
To heat a steel band to 1000 ºF (538 ºC) and insert a carbon graphite ring into the center of the steel band.
Brazing a heat-sensing probeA C-shaped steel susceptor is used to ensure even heating and for ease of loading and unloading the samples.
Brazing Carbide Tips on Drill Bits
A brazing temperature of 1900°F was reached through the use of a unique 4 turn helical coil. D
A levitation melting system for micro-gravity metal processing
Design a modular electromagnetic levitor (MEL) to aid in the study of RF systems used to process metals in the microgravity of space.
Annealing steel tubes in an inert atmosphere
Induction annealing heats steel tubes to 2000 ºF (1093 ºC) in an inert atmosphere for very small areas within precise production tolerances. A two-turn concentrator coil is used to heat the stainless steel tube. The annealing process takes place in an inert atmosphere to prevent oxidation.
Heating a catheter tipping die
A two turn plate concentrator coil is used to heat the die. To measure the temperature on the ID and establish the time-to-temperature relationship...
Heat Setting A Shape Memory Alloy
Heat a steel die to 975°F (523.8ºC) to set (cure) a shape memory alloy nitinol in the correct position.
Molding a teflon catheter tipHeat a water-cooled steel mandrel to 700°F (371ºC) to form a high quality Teflon catheter tip.
Plastic Reflow With Catheter Tubing
Heat a metal braid in a plastic catheter tube to 250°F (121.1ºC) so that another catheter tube can be bonded to it.
Levitation melting of steel balls
Benefits: Minimal contamination of conductive material during manufacturing, removal of insoluble inclusions while leaving desired alloying constituents intact, even distribution of heating
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