UltraFlex brazing heat exchanger tubes with induction at less than 35 second each
The result from this test scenario was a reliable, high-quality and time-efficient brazing process that eliminated costly delays in brazing processing.
The customer asked to compare results from torch-based brazing for a heat exchanger to induction brazing. The brazing process required that U returns be brazed to the receiving tubes of a heat exchanger, so those returns could then be used to flow the water through the heat exchanger, and keep the unit cooled.
For this test application, UltraFlex used their Low Power Induction System from the UltraHeat S series. UltraHeat S induction heaters are compact, economical and versatile 2 kW induction heating systems, utilizing the latest switching power supply technology.
Two brazing tests were done per customer's request - with and without using flux. The flux test was done by pre-coating the U-return braze ring and receiving tube with white braze flux. Then, the heat exchange unit was assembled using 13U returns. In the no-flux test, the unit was assembled without flux.
The assembly was positioned for brazing its components by moving the coil and heat station up/down. A copper shield "comb" was placed under four receiving tubes to shield the plated carbon steel plate from the RF Field. The section was then heated to let the phosphor bronze alloy pre-formed rings to braze on both sides of the U-bend simultaneously.
At power output of 2.35 kW and target brazing temperature of 1400-1450°F (760-788°C)
The result from this test scenario was a reliable, high-quality and time-efficient brazing process that eliminated costly delays in brazing processing. Thanks to the precise digital control of the time and temperature, the power supplied on-demand as well as rapid heat cycles, the process was time-efficient but also energy- and cost-efficient. The brazing process was not dependent on operator and hence consistency of the end result was guaranteed.
In addition, since induction-based heating is a no-flame heating, the entire brazing process was a completely safe and green operation.
About UltraFlex Power Technologies:
UltraFlex Power Technologies (ultraflexpower.com) offers the most advanced and innovative digitally controlled induction heaters in the industry. Its compact modular and flexible systems are suitable for a wide variety of induction heating, casting and melting applications.
UltraFlex Power Technologies