Induction brazing is undeniably more precise and efficient than conventional brazing with a torch, but the process can solve other brazing problems manufacturers face. It can be difficult to control the temperature in a specific section of a workpiece while brazing with a torch – especially when brazing large parts. The following case study explains how brazing using high power induction can connect large parts with strong joints that will last. Watch the video.
The problem: the joint was not hot enough to connect
Part A is a section a copper circuit ring. Part B is the copper tap connection.
Recently, a customer came to eldec with a dilemma. While initially attempting to repair the stator for a hydroelectric generator by brazing with a torch, the repairman found he struggled to get the joint hot enough to create a good connection. Since his torch was inefficient, the heat travelled down the length of the copper circuit ring so quickly that the joint could not achieve brazing temperature and the joint would not hold.
The customer’s repair project included a large brazed connection where a section of the generator’s copper circuit ring (A) met the smaller diameter copper tap (B) on the circuit ring. The larger piece measured approximately 4” OD and 2.8” ID with a flat area for brazing measuring 3.5” along the tube and 5.5” wide. The smaller piece had a 2” OD and 1” ID and a flat area for brazing that was 2.5” wide by 4.5” long.
The solution: heat the joint faster with 100 kW power supply
eldec’s highly experienced technicians reviewed the customer’s project and problem and suggested brazing with a high-powered induction generator rather than a torch. We recommended our MFG 100 power supply with a standard, handheld coax transformer for this application. The main advantage of the 100kW induction power supply in this situation was that since it met the necessary power requirements, it allowed the joint to be heated at a faster rate than that of the energy transfer down the length of the copper circuit ring. Using eldec’s MFG 100 induction generator as well as an eldec custom fabricated, straight fork induction coil, the customer was able to repair the part on-site and braze this connection in approximately three to five minutes with 100kW. The new joints were precise and strong, and the rest of the workpiece remained distortion-free and unaffected by the heating process.
Video below shows how the process works.
The video has been sped up in order to make viewing the process easier.
To learn more about eldec’s 100kW induction power supply, the MFG 100, or to discuss your project in your specific environment, please give us a call or send us a request and we’ll contact you.