Induction Soldering

What is induction soldering?

Induction soldering is a process in which two conductive materials are joined using a filler metal or other material that melts at a low temperature. This differs from brazing because it is performed at lower temperatures.

Induction generates an electromagnetic field in a work coil that induces currents in the conductive material of a workpiece placed within or near the coil. Friction from these currents heats the workpieces and solder.

soldering Application Notes

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

image: Desoldering Customer Assemblies with Induction Heating 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.

image: Soldering Brass and Copper Components 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.

image: Heating a Copper Assembly for Soldering 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.

image: Soldering Ferrule and Module Assembly Soldering Ferrule and Module Assembly

To heat ferrule and module assemblies for a soldering application in the fiber optics industry.

image: Soldering Co-axial Wire to a Metal Frame 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.

image: Heating a Kovar Ferrule for Glass Soldering 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

image: Soldering Four Fusible Copper Strips 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

image: Soldering a pair of magnetic steel pins 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.

image: Soldering a rivet onto a steel tank cap with induction heating 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.

image: Soldering copper tabs for stringing, tabbing solar panels 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...

image: Soldering electrical wire to a copper grounding 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

image: Soldering brass and steel radiator caps 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...

image: Soldering a copper tube to a brass valve [flow valve] 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.

image: Soldering a copper wire, contactor assembly [motor] 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.

image: Hermetic Sealing a Ferrule & Fiber Optic Cable 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

image: Soldering a fine copper wire to an electrical connector assembly 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.

image: Soldering a steel canister for sealing 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.

image: Solder Fiber Optic Cable to Ferrule & Preform Solder Fiber Optic Cable to Ferrule & Preform

Induction heating provides rapid localized heat only where needed, repeatable, consistent results with clean, controllable joints

image: Soldering a steel funnel to flex spout Soldering a steel funnel to flex spout

Induction heating delivers non-contact energy-efficient heat without flame, resulting in repeatable and consistent results

image: Hermetically sealing a fiber optic cable in a kovar ferrule 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

image: Soldering windows to time indicator housings Soldering windows to time indicator housings

Soldering soda lime glass metal edged windows to steel time

image: Soldering a copper chip to a silver dipped brass RF attenuator 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

image: Soldering electrical wires onto three connector tabs on a three position wall socket plug 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.

image: Soldering 3 copper spacers to circuit board simultaneously 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

image: Soldering Electrical Flex Circuits Soldering Electrical Flex Circuits

To heat multiple joints on flex circuit strips to 180-200°F within seven seconds for a soldering application.

image: Soldering a Radio Antenna Soldering a Radio Antenna

To 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.

image: Soldering Solar Flex Circuits Soldering Solar Flex Circuits

Heat multiple joints on solar flex circuit strips to 500°F (260°C) within ten seconds for a soldering application.

image: Soldering three fuse caps simultaneously 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

image: Soldering three brass connectors in a solar panel junction box assembly 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

image: Soldering a steel cover onto a nickel plated EMI filter 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

image: Soldering 2 electrical wires to copper buss bar Soldering 2 electrical wires to copper buss bar

Induction heating delivers reduced solder time, even distribution of heating and improved joint-to-joint consistency

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: Soldering connector to wire harness Soldering connector to wire harness

Induction heating provides reduced production cost, faster process time, hands-free heating that involves no operator skill for manufacturing

image: Soldering two connectors simultaneously to gound plate 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

image: Soldering fabric to kovar tip assembly 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

image: Soldering a kovar piece with glass to a copper base for a photon light source 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

image: Soldering brass and copper (anesthetic medical equipment) 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...

image: Soldering circuit board posts with lead or lead free solder preforms 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

image: Soldering Brass end cap on heat exchanger 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

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: Soldering of satellite antennas 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

image: Soldering electrical wires onto connector assemblies 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.

image: Soldering Co-axial Wire Assemblies 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.

image: Soldering a copper tab on a speaker ring 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.

image: Soldering a Stainless Steel Tube to Cylinder 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

image: Soldering Steel Housing Soldering Steel Housing

A 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...

image: Soldering Cellular Phone Antenna 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.

image: Soldering Ice Machine Evaporator assemblies 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.

image: Soldering Brass Bellows Assembly 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.

image: Soldering Steel Connectors to a Brass Block 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

image: Soldering Brass Slip Ring Soldering Brass Slip Ring

To 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...

Benefits of Soldering with Induction

Induction soldering delivers precise, localized heat, increases production rates with faster heating cycles and reduces defect rates with repeatable, reliable heating, eliminating variability from part to part, while maintaining metallurgical characteristics of the individual metals.

This is accomplished without open flame or the restrictions of a batch process.

Do you have a soldering guide?

Why use induction for soldering?

Induction soldering delivers energy only where it's needed, so it delivers faster heating times, reduces potential for process error, enhances process control and saves energy.

How does soldering differ from brazing?

Soldering is performed at lower temperatures than brazing and may result in a slightly weaker joint, but one that's preferable for some applications such as those involving small components.

Can soldering and brazing be done with one system?

The amount of power available in the induction system determines if you can use the same system.

What materials can be soldered with induction?

Induction soldering is a highly effective method specifically designed for joining electrically conductive materials. It offers exceptional results when working with materials like copper, brass, steel, and aluminum. This technique utilizes electromagnetic induction to generate heat, which is then applied to the workpiece, melting the solder and creating a strong bond between the materials. The advantage of induction soldering lies in its ability to precisely control the heat distribution, ensuring a uniform and reliable connection. Additionally, this process minimizes the risk of thermal damage to the surrounding areas due to its localized heating feature. By harnessing the power of induction soldering, manufacturers can achieve efficient and high-quality soldering for a wide range of applications in industries such as electronics, automotive, and plumbing.