Tailored Induction Brazing Solutions

KEXIN specializes in induction brazing, delivering tailored solutions for industries like automotive, aviation, and electronics. Our systems provide precise and uniform heating, reduce distortion, and ensure reliable material bonding. Our expertise guarantees quality performance and energy efficiency for a variety of applications.

    KEXIN Induction Brazing Machines

    KEXIN offers advanced induction brazing machines that join metals efficiently using induction heating. The process utilizes a filler material that melts and flows at a temperature lower than the base metals, bonding them without altering their structure. By generating an electromagnetic field in a work coil, induction brazing elevates the temperature of the materials and filler through induced currents, achieving precise, uniform heating.

    KEXIN’s systems, featuring high-frequency, medium-frequency, and ultrasonic options, adapt to diverse industrial needs. With modular designs and customizable solutions, these machines integrate into automated workflows for industries like automotive, aerospace, and energy.

    What Is Induction Brazing

    What Is Induction Brazing?

    Induction brazing joins two or more materials using a filler metal with a lower melting point than the base materials. The process uses induction heating, where an alternating current in the coil generates an electromagnetic field. The electromagnetic field rapidly heats ferrous materials, enabling precise and efficient joining.

    Magnetic materials are heated quickly due to their properties, while non-magnetic materials like ceramics may require conduction from metallic parts or a susceptor to achieve the desired temperature.

    Induction brazing is preferred in industrial applications for its advantages. It offers selective heating, improves joint quality, reduces oxidation, speeds up heating cycles, and ensures consistent results. It is also effective for large-scale production.

    The Basics of Induction Brazing

    Induction brazing is a sophisticated technique for joining metals, utilizing electromagnetic induction to generate heat. This method ensures localized heating, precise temperature control, and a non-contact heating process, making it efficient and repeatable.

    The Role of Electromagnetic Fields in Induction Brazing

    The induction brazing process operates using an electromagnetic field created by a specially designed coil. When high-frequency alternating current flows through the coil, a magnetic field forms around it. The magnetic field interacts with the conductive material of the workpiece, inducing eddy currents. These currents generate heat through electrical resistance within the material.

    The heat produced is highly localized, enabling precise temperature control. This ensures the filler material melts and flows only at the joint, creating a strong bond. The electromagnetic field’s efficiency makes the brazing process clean and minimizes the impact on the workpiece structure.

    Induction Brazing

    How Induction Brazing Works

    Heating Generation Through Electromagnetic Field

    A high-frequency electromagnetic field focuses heat on a specific area of the workpiece. This targeted heating allows the filler metal to melt and fill the joint surfaces.

    Transformer Principle

    The induction coil acts as the primary winding to create a magnetic field. The workpiece, functioning as the secondary winding, receives heat through this interaction.

    Eddy Currents Generation

    Induction creates eddy currents in the workpiece, producing heat through electrical resistance. The heat will be directed precisely to the joint area.

    Controlled Heating Process

    The localized nature of the heat prevents thermal distortion. It ensures the bond forms accurately and remains strong in critical applications.

    The Advantages of Induction Brazing

    Selective Heating

    Induction heating targets small areas with precise control, focusing heat only where it is needed, near the joint. The rest of the part remains unaffected, preventing damage. This method also eliminates issues like distortion and metal fatigue, which are common with repeated exposure to heat. Coil design and fixturing allow heat to be applied in different areas of the same part, maintaining consistency.

    Better Quality Joints

    Induction heating creates clean, leak-proof joints by controlling where the filler material flows. This precision is especially important for high-reliability, high-precision applications. Induction brazing prevents filler from reaching unwanted areas. It ensures better joint quality.

    Reduced Oxidation and Cleaning

    Traditional flame heating causes oxidation and requires flux and acid cleaning, adding time and cost. Induction brazing reduces oxidation and the need for cleaning, especially when using a rapid cool-down cycle. This process minimizes the need for expensive cleaning and improves overall part quality.

    Fast Heating Cycles

    Induction brazing has a shorter heating cycle compared to flame brazing, enabling faster processing of parts. The localized heat reduces part warpage and distortion. Additionally, brazing in a controlled vacuum or inert atmosphere enhances part quality and eliminates cleaning procedures.

    Induction Brazing For Various Applicaions

    Induction brazing for wrench tools

    Induction brazing for wrench tools

    Induction brazing for dispenser copper pipes

    Induction brazing for dispenser copper pipes

    Induction brazing for Air-cooled heat exchanger

    Induction brazing for Air-cooled heat exchanger

    Induction brazing for stainless steel parts

    Induction brazing for stainless steel parts

    Induction brazing for T-shaped copper assemblies

    Induction brazing for T-shaped copper assemblies

    Induction Brazing of Aluminum Radiators

    Induction Brazing of Aluminum Radiators

    Industrial Of Induction Brazing

    Induction brazing is a fast and efficient method of joining metals without the need for external pressure or filler material. This process is widely used in various industrial to create strong and durable brazing. It is widely used in various industrial:

    Automotive Industry

    Automotive Industry

    With the advantage of easy to control and monitor, induction brazing is used within a variety of fields in the production of electric cars, the brazing of virtually any body panel, chassis, driveline, electrical or engine part of a vehicle.

    Renewable Energy

    Renewable Energy

    Induction brazing is used for wind turbine component production and assembly. You can use induction for heating a large number of metal parts in wind power systems – from brazing of terminal ends on high voltage cables to hardening inclined heavy rings of more than five meters in diameter.

    Appliances Industry

    Appliances Industry

    Induction brazing is accurate, controllable and repeatable. Induction brazing is used for brazing of bars, strands, rings and wires in motors, generators and transformers. Other applications include brazing and hardening compressor parts in refrigerators and freezers, as well as bonding of fridge bodies and tube welding.

    FAQS

    01.What is an induction brazing?

    Induction brazing is a type of brazing that fuses two or more metals together using the resistive heat caused by changing electromagnetic fields, otherwise known as induction. During induction brazing, a work piece is surrounded by conductive coils. The changing magnetic field is typically induced through the use of an alternating current that runs through the conductive coils.

    02.Why should I buy an induction brazing machine?

    Induction brazing machines are used because they offer efficiency, fast heating, safety, cleanness, and accurate control. They are the fastest method for hardening and heat treating, resulting in minimal distortion and a fine-grain microstructure. Induction brazing is accurate, fast, repeatable, and efficient, making it suitable for precise or repetitive operations. It is a rapid, energy-efficient, flameless method of heating electrically conductive materials.

    03.What are the advantages of induction brazing machine?

    High efficiency and energy saving.  It can save 2/3 of the power than the high frequency of the electron tube.

    Low maintenance costs. No fragile and expensive tubes.

    Special Safety: No high voltage, eliminating the danger of high voltage electric shock.

    Easy to Install: Just connect the power supply and water pipes; it can be completed in 10 minutes.

    Easy operation: user can learn in a few minutes.

    04.How to choose the frequency of induction brazing machine?

    For different workpiece materials, sizes and shapes, the frequency will be different accordingly.

    Please send inquiry to us, we will recommend the optimal induction heating machine on your request.

    05.How to choose the cooling system for induction brazing machine?

    We will recommend the most suitable cooling system based on different brazing requirements.

    06.Do I need to buy a cooling system separately for KEXIN induction brazing machine?

    Yes, you can prepare a water tank and a water pump to work as cooling system; Or you can directly prepare a cooling chiller.

    07.How long is the warranty period?

    We provide one-year warranty for the induction heating machines. Even when the induction heating machine is disorder or doesn’t work, you can send videos or photos to us; our engineers will analyze and check out the problems, then provide the spare parts to you for replacement. And we provide life -long technical support and other assistance.

    08.What shapes and sizes of parts can be brazed?

    A wide variety of shapes and sizes can be brazed, including pipes, rods, and complex geometries.

    09.What materials can be joined with induction brazing?

    Most metals, including ferrous and non-ferrous alloys, can be joined. Some ceramics may also be brazed if paired with suitable materials.

    10. What equipment is required for induction brazing?

    An induction heating machine, a coil, and appropriate fixturing are needed, along with filler metals and flux when necessary.

    11. What is the difference between induction brazing and welding?

    Induction brazing melts only the filler metal, leaving the base materials intact. Welding melts the base materials to join them.

    12. What is the difference between high-frequency and medium-frequency induction brazing?

    High-frequency is suitable for small parts and surface heating, while medium-frequency is better for larger parts and deeper penetration.

    13. Can induction brazing be automated?

    Yes, many systems integrate with automated production lines for efficiency and consistency.

    14. What are the safety considerations for induction brazing?

    Proper shielding, grounding, and protective gear are essential to avoid exposure to electromagnetic fields and high temperatures.

    15. How does induction brazing minimize oxidation?

    Induction brazing can be performed in protective atmospheres or with flux, reducing oxidation.

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