Induction brazing typically takes a few minutes to complete once the setpoint temperature is reached, followed by a slow cooling period to solidify the filler metal. The exact duration can vary based on several factors including the composition of the base metal and braze alloy, the mass of the assembly, and the joint design.
Detailed Explanation:
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Heating Phase: The induction brazing process begins with heating the parts to a temperature just below the solidus temperature of the braze alloy. This initial heating phase should not exceed a rate of 15°C (30°F) per minute to prevent issues like spalling of the braze alloy or distortion of the assembly. This step ensures that the parts are uniformly heated and ready for the brazing process.
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Soak Phase: After reaching the stand-off temperature, typically about 25°C (50°F) below the braze alloy's solidus temperature, the parts are soaked at this temperature for about 30 minutes. This soak time is crucial for ensuring temperature uniformity across the assembly and allowing the vacuum levels to recover if the process is conducted in a vacuum environment.
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Ramp-up to Brazing Temperature: Following the soak, the temperature is ramped up more quickly, at a rate of 15°C to 25°C (30°F to 50°F) per minute, to reach the brazing temperature. This faster rate is necessary to prevent liquation of the braze alloy and to minimize the risk of base metal erosion.
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Brazing and Cooling: Once the brazing temperature is reached, the actual brazing process occurs, which is typically quick, lasting only a few minutes. After brazing, the parts are allowed to cool slowly to about 980°C (1800°F) to ensure that the filler metal solidifies properly. Rapid cooling can be achieved by gas quenching, which is often used in industrial settings to speed up the process.
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Post-Brazing Processes: Depending on the application, additional steps such as heat treatment or sealing might be performed after the brazing process to enhance the properties or functionality of the joint.
The overall time for induction brazing, from heating to cooling, can range from a few minutes to several hours, depending on the specific parameters and requirements of the brazing cycle. The repeatability and uniformity of induction brazing make it a preferred method for high production runs, ensuring consistent and reliable results.
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