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Induction brazing uses induction heating to melt a filler material and join two metal pieces without changing their state. The process is rapid, precise, and eco-friendly, but joining dissimilar metals requires careful consideration. It can be used in various environments and for various applications.
Induction brazing is a process of joining two pieces of metal using a molten filler material obtained by induction heating. This heating is achieved by placing work inside an induction coil and passing an electric current through the coil. This creates electrical currents, known as eddy currents, in the materials to be joined. The heat is generated by the electrical resistance to the eddy currents of the materials to be joined. This heat is used to melt the filler material to be used in joining the two metal pieces, but these pieces remain in a solid state throughout the process.
To begin an induction brazing operation, the first step is usually to treat the parts to be joined with a material known as flux. The filler material is then placed on the work, usually with the aid of some sort of form to keep it in place. Alternatively, the brazing material can be applied to the work once the parts have been brought up to the required temperature.
The work is placed inside an induction coil, through which a high-frequency electric current is passed. When currents are induced in the surfaces of the workpieces to be joined, their intrinsic electrical resistances oppose those currents and the workpieces heat up. The filler material melts under this heat and forms a bond between the two pieces as the assembly cools.
While the filling material melts, the pieces to be joined remain in a solid state. This means that the melting temperature of the filler material must be lower than that of the materials to be joined. Silver and silver alloys, as well as copper, are often used as filler materials for this reason.
One of the main advantages of induction brazing is that heating is rapid, localized and precisely controlled. This leads to a very reproducible process suitable for high speed production. Induction brazing is also an environmentally friendly practice that consumes less energy than other joining methods and produces no combustion by-products as there is no flame involved. The highly localized heating in induction brazing minimizes distortion or other physical changes to the parts being joined.
Similar metals join more easily with induction brazing. It is possible to join dissimilar metals, but this requires much more consideration. The different current resistances of different materials cause the parts to heat up at different rates and temperatures. They can also have different rates of thermal expansion, which further complicates the task.
Induction brazing operations can occur in a variety of environments. Pieces can be joined while immersed in a liquid, in air or another gaseous atmosphere, or even in a vacuum. Many types of brazing operations can be performed with induction brazing. Applications vary widely and include examples such as the manufacture of dental instruments and orthodontic components, as well as the manufacture of fuel lines and brake parts in automotive assembly.
