Differences and advantages of induction brazing and flame welding

Principle of induction brazing

Induction brazing is to place the metal workpiece to be welded (mostly red copper) in the induction coil, apply high-frequency alternating current to generate an induced electromagnetic field, couple the surface of the workpiece to generate an induced electromotive force, form an induced eddy current on the metal surface, rely on the eddy current generated on the metal surface to generate heat, and generally apply welding powder to the welding part until the workpiece reaches the melting temperature of the brazing filler metal.

Induction brazing, also known as induction brazing, has many advantages over welding by flame or in an oven. The process is popular for its speed, precision, repeatable heating and reliability.

Principle of flame welding

The high-temperature flame generated by the mixture of combustible gas and combustion-supporting gas is used to melt the part to be welded of the workpiece, and the filling material is filled into the molten pool, so that the molten metal forms a common molten pool. As the heat source moves forward continuously, the part leaving the heat source begins to cool, the molten pool solidifies, and finally a weld is formed.

Flame welding, also known as gas welding, the use of combustible gas and oxygen (or compressed air) mixed combustion flame for heating welding.

Differences and advantages of induction brazing and flame welding

Energy consumption:

Energy saving: 10.6-3.8=68000 yuan
Welding material consumption:

According to the above calculation, 1000 small pressure plates are welded:

Manual welding costs 1000 × 180/1400=128.6 yuan;

High frequency brazing costs 1000 × 180/2000=90 yuan.

Material saving:(128.6-90)/128.6 = 30%

Production efficiency:

Welding process equipment, reduce the dependence on manual technology, can be replaced by ordinary operators licensed flame welders.

In small workpieces and few pipes, the advantages of induction brazing are not obvious. However, the induction brazing welding process is automatic welding of the equipment, manual operation is not required, and another equipment can be operated by using the welding time, which can further increase the output.

Advantages of induction brazing

1. Uniform and stable heating;

2, the process has accurate repeatability;

3. Induction brazing has the highest safety;

Minimization of energy demand;

5. Simple and safe operation;

6. The porosity and weak solder joints can be reduced to a minimum;

7, cold solder joints reduced to a minimum.