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MAGNETIC FLUX CONTROLLERS FOR NEW INDUCTION BRAZING INSTALLATIONS

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MAGNETIC FLUX CONTROLLERS FOR NEW INDUCTION BRAZING INSTALLATIONS

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MAGNETIC FLUX CONTROLLERS FOR NEW INDUCTION BRAZING INSTALLATIONS

  1. 1. INDUCTORSWITH MAGNETIC FLUX CONTROLLERS FOR NEW INDUCTION BRAZING INSTALLATIONS Dr. V. Nemkov1 and Dr. V. Vologdin 2 (1) Centre for Induction Technology, USA (2) FREAL, Ltd., Vologdin High Frequency Currents Institute, Sankt Petersburg, Russia
  2. 2. Induction Brazing Updates• New compact power supplies with any desired frequency• New fluxes and filler metals including amorphous materials• New magnetic materials for heat pattern control• Computer simulation design
  3. 3. Pipe to Tube Induction Brazing Installation using “Horseshoe-Hairpin” Coil Connection Block Pipe Joint Fluxtrol A Magnetic Flux Controller Copper Coil Tube Header Body
  4. 4. 3D Computer Simulation of AL Pipe to Tube Brazing Copper Coil Pipe Top Concentrator Tube Central concentrator Header Bottom concentrator
  5. 5. Example of Computer-Assisted Design of Brazing Inductor Brazing of Pipe to Nipple of Aluminum Heat Exchanger Pipe Tube Header Fluxtrol controller system
  6. 6. Two-Station Induction Installation for Manual Brazing Two Transistor generators Heat Station 10 kW 66 kHz
  7. 7. Brazing of Copper Crossovers to Heat ExchangersTinned steel plate Crossover L-shaped Inductor copper controller
  8. 8. Power Supply for Brazing Manufacturer – Freal, Ltd., St. Petersburg Generator Power 10 kW; Frequency 66 kHz; Weight 12 kg Cooling – Forced Air
  9. 9. Brazing of Heavy Copper Bussbars for Nuclear Plants Length up to 4 metres, cross-section up to 3000 mm2 More than 500 joints per coil
  10. 10. Brazing of Heavy Copper Bussbars for Nuclear Plants Two-inductor system for balanced heating of parts Power 100 kW; Frequency 10 kHz Fluxtrol concentrators
  11. 11. Brazing of Heavy Copper Bussbars for Nuclear Plants Fluxtrol controllers Close-up of induction coil attached to a special transformer with amorphous magnetic core
  12. 12. Even Small Concentrators Drastically Improve Coil Performance ConcentratorsBrazing of steel tube to Brazing of hard plates to mill bitsprofile with clamshell inductor Red spot – laser pointer of IR pyrometer
  13. 13. Conclusions• Compact installations for induction brazing processes are possible with new power supplies• Magnetic Flux Concentrators play big role in improvement of process quality and efficiency• Fluxtrol A, 50 and Ferrotron 559 materials perform well in brazing of copper, aluminum and steel components

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