Induction Brazing Aluminum

What is Induction Brazing Aluminum?

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

brazing aluminum Application Notes

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

image: Brazing an Aluminum Tube Assembly 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

image: Heating Wires and Strips for Coating Removal 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

image: Heating an Aluminum Tube for Bending 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

image: Heating aluminum wire to create screens 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

image: Brazing aluminum adaptors to the end of aluminum tubes 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.

image: Tempering an audio speaker screen 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

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

image: Brazing tubes and fittings for an air conditioning unit for the off-road market 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...

image: Brazing an aluminum assembly for a bicycle manufacturing application 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...

image: Brazing an aluminum manifold [air conditioning] 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..

image: Preheating aluminum flanges 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

image: Pre-heating aluminum wheels prior to spray painting 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.

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

image: Heating top of aluminum oxygen tank for end forming 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

image: Brazing aluminum electrical lug assembly 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...

image: Induction Bonding Aluminum & Carbon Fiber Coupons 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).

image: Shrink Fitting an Aluminum Tube 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

image: Heating aluminium susceptor for powder expansion Heating aluminium susceptor for powder expansion

Expand powder into solid form for use in crash helmets

image: Shrink fitting an automotive aluminum motor housing 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

image: Soldering an LED assembly to an aluminum spotlight housing 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

image: Inserting a Steel Bushing to an Aluminum Hub 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

image: Annealing aluminum fuel tank fill neck for bending 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.

image: Curing a coating; both sides aluminum piston 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.

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

image: Curing epoxy on aluminum copier roller assembly 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.

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

image: Curing plastisol adhesive on an aluminum filter assembly 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.

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

image: Bonding Foil to a Plastic Bottle 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.

image: Curing ink on aluminum bottle caps 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.

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: Curing Alumium Car Molding Curing Alumium Car Molding

Automotive manufacturers are constantly searching for cost-effective production technologies.

image: Sealing an aluminum disk onto a plastic cap 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.

image: Induction Melting aluminum in a graphite crucible for casting 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.

image: Cap Sealing; Shampoo Container 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.

image: Heating Aluminum Auto Trim for Adhesive Curing Heating Aluminum Auto Trim for Adhesive Curing