Induction Brazing Aluminum

Why Braze Aluminum with Induction Heating?

Induction brazing aluminum addresses the issues of torch and furnace brazing by removing the requirement for a skilled operator, by reducing energy costs and by decreasing the equipment footprint while implementing a lean manufacturing process for higher quality parts.

Induction brazing aluminum Benefits 

  • Meets tight production tolerances with precise localized heat to small areas creating pinpoint accuracy

  • Increases production rates with faster heating cycles

  • Reduces defect rates with repeatable, reliable heat

  • Eliminates variability from operator-to-operator, shift-to-shift

  • Maintains metallurgical characteristics of the individual metals

induction brazing aluminum
Select an option below:

brazing aluminum Application Notes

Select from our collection of brazing aluminum notes, developed over 39 years supporting our customers. Read how we helped to solve their process heating challenges!

image: Brazing an Aluminum AssemblyBrazing an Aluminum Assembly

The target temperature can be achieved within 157 seconds with the EASYHEAT 6 kW power supply. A good solid joint resulted from the heating process.

image: Brazing an Aluminum Tube AssemblyBrazing 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

image: Sealing an Aluminum Cap Seal on a Plastic JugSealing 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.

image: Bonding Aluminum & Carbon Fiber CouponsBonding Aluminum & Carbon Fiber Coupons

Bonding aluminum & carbon fiber coupons with induction Testing from THE LAB confirmed the feasibility of the heating process for the customer. 

image: Annealing aluminum fuel tank fill neck for bendingAnnealing 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.

image: Brazing aluminum adaptors to aluminum tubesBrazing aluminum adaptors to 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.

image: Brazing an aluminum bicycle assemblyBrazing an aluminum bicycle assembly

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...

image: Brazing an aluminum AC manifoldBrazing an aluminum AC manifold

Precise, repeatable heating: The client wanted more precise and repeatable heating than a torch could deliver, which induction was able to achieve..

image: Brazing two aluminum pipes to an aluminum evaporator coreBrazing 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...

image: Brazing aluminum electrical lug assemblyBrazing 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...

image: Bonding Foil to a Plastic BottleBonding 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.

image: Sealing an aluminum disk onto a plastic capSealing 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.

image: Cap Sealing; Shampoo ContainerCap 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.

image: Heating Catheter Tipping DieHeating Catheter Tipping Die

To heat an aluminum catheter tipping die to above 285 °F within 2 to 5 seconds for the forming of catheter material.

image: Curing a coating; both sides aluminum pistonCuring a coating; both sides aluminum piston

A three-turn channel coil 19 in (48.26 cm) long is used to anneal 4 pistons running though the coil with a distance of 6 in (15.24 cm) between centers.

image: Curing epoxy on aluminum copier roller assemblyCuring 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.

image: Curing ink on aluminum bottle capsCuring 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.

image: Heating Wires and Strips for Coating RemovalHeating 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

image: Heating an Aluminum Tube for BendingHeating 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

image: Heating aluminum wire to create screensHeating 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

image: Tempering an audio speaker screenTempering 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

image: Heating an aluminum-backed circuit board - solder reflowHeating an aluminum-backed circuit board - solder reflow

Given the significantly faster heating time, induction improves throughput in this process and is a more efficient heating method than hot plate heating

image: Preheating aluminum flangesPreheating aluminum flanges

Induction 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

image: Pre-heating aluminum wheels (spray painting)Pre-heating aluminum wheels (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.

image: End-forming top of aluminum oxygen tankEnd-forming top of aluminum oxygen tank

Through heating the top 2 in (50.8 mm) of aluminum oxygen tank to form a rounded end with a hole for oxygen valve

image: Melting aluminum in a graphite crucible for castingMelting 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.

image: Shrink Fitting an Aluminum TubeShrink 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

image: Shrink fitting an automotive aluminum motor housingShrink 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

image: Shrink Fitting an Aluminum Motor HousingShrink 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.

image: Shrink-fitting auto turbo charger impeller blades onto an aluminum shaftShrink-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

image: Shrink fitting aluminum pulley to insert inner bearing 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.

image: Soldering an LED assembly to an aluminum spotlight housingSoldering 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

image: Reflowing the solder of an area on a circuit boardReflowing 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...

brazing aluminum Application Notes

Thank you Friend for trusting us with your brazing aluminum inquiries. Read any of our application notes below without registration.


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

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...

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

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

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.

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

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.

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.

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

Heating an aluminum-backed circuit board - solder reflow

Given the significantly faster heating time, induction improves throughput in this process and is a more efficient heating method than hot plate heating

Preheating aluminum flanges

Induction 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

Pre-heating aluminum wheels (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.

End-forming top of aluminum oxygen tank

Through heating the top 2 in (50.8 mm) of aluminum oxygen tank to form a rounded end with a hole for oxygen valve

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

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

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

Curing a coating; both sides aluminum piston

A three-turn channel coil 19 in (48.26 cm) long is used to anneal 4 pistons running though the coil with a distance of 6 in (15.24 cm) between centers.

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.

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.

Heating Catheter Tipping Die

To heat an aluminum catheter tipping die to above 285 °F within 2 to 5 seconds for the forming of catheter material.

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.

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.

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.

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.

Brazing aluminum adaptors to 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.

Brazing an aluminum bicycle assembly

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...

Brazing an aluminum AC manifold

Precise, repeatable heating: The client wanted more precise and repeatable heating than a torch could deliver, which induction was able to achieve..

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...

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...

Brazing an Aluminum Assembly

The target temperature can be achieved within 157 seconds with the EASYHEAT 6 kW power supply. A good solid joint resulted from the heating process.

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

Bonding Aluminum & Carbon Fiber Coupons

Bonding aluminum & carbon fiber coupons with induction Testing from THE LAB confirmed the feasibility of the heating process for the customer. 

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.

Induction brazing aluminum Resources:

Select from our libraries of materials to help you better understand the benefits brazing aluminum with induction heating can bring to your process.

Four Ways To Contact Ambrell for Support

AMBRELL CORPORATION

1655 Lyell Avenue
Rochester, NY 14606
United States
 

Directions to Ambrell Corporation Directions

T: +1 585 889 9000

F: +1 585 889 4030

Contact Sales

Contact Orders

Contact Service

S: +1 585 889 0200

AMBRELL B.V.

Holtersweg 1
7556 BS Hengelo
The Netherlands
 

Directions to Ambrell B. V. Directions

T: +31 880 150 100

F: +31 546 788 154

Contact Sales

Contact Orders

Contact Service

AMBRELL Ltd.

Unit 6, Space Business Centre
Tewkesbury Road
Cheltenham, GLOS, GL51 9FL
United Kingdom

Directions to Ambrell Ltd.Directions

T: +44 1242 514042

F: +31 546 788 154

Contact Sales

Contact Orders

Contact Service