Note: Brazing copper tubes to a brass manifold block

Objective:

Heating a brass block and two copper tubes to 1400 °F (760 °C)

End Product:

Brass block

Equipment:

Ambrell 2.4 kW, 150-400 kHz solid state induction heating system equipped with a remote heat station containing two 0.66 μF capacitors (total 1.32 μF) A multi-turn helical coil

Materials:

Brass block (diameters of .25 in /6.35mm and .375 in /9.5mm) Copper tubes Braze pre-forms Flux 

Temperature:

1400 °F (760 °C)

Frequency:

106 kHz

Testing:

The copper tubes and brass block were fluxed, assembled, and placed into the induction coil. There were two assemblies. The .375 in /9.5mm copper block assembly had more mass and required 90 seconds to bring it to temperature. The .25 in /6.35mm copper block assembly was heated to temperature within 60 seconds. Faster cycle times were tried in both cases, but localized melting occurred.

Benefits:

  • Speed: The proposed process met the client"s time objective, and is faster than oven heating

  • Part quality: The client was suffering from part quality issues and rejects while using an oven; induction offers a good quality braze joint

  • Floor space: Induction uses less floor space than an oven

  • Energy efficiency: Ovens take time to warm up and use more energy than induction, which has instant on/off

Brazing copper tubes to a brass manifold block

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