Induction brazing condenser tubes

Induction brazing condenser tubes is a process of joining copper tubes to a diverter valve using induction heating. Induction heating generates an electromagnetic field in a coil that induces currents in the conductive material of the tube and the valve. The heat from these currents melts the filler metal and creates a strong bond between the tube and the valve.

Induction brazing condenser tubes can improve production efficiency, quality, and safety compared to torch brazing. Induction brazing can be automated and guarantee consistent and repeatable brazing results. Induction brazing also eliminates the open flame and reduces the heat input to the surrounding environment.

One example of induction brazing condenser tubes is shown in this video, where an automated in-place induction brazing system is used to braze 19 condenser units with different sizes and shapes. The system uses a custom-designed coil that can adjust to the geometry of each unit and provide uniform heating. 

How do braze condenser tubes with induction heating?

Brazing is a process for joining two metals with a filler material that melts, flows, and wets the metals’ surfaces at a temperature that is lower than the melting temperature of the two metals. Induction heating is a method of brazing that uses an electromagnetic field to heat the parts and melt the filler material.

To braze condenser tubes with induction heating, you need to follow these steps:

- Design the joint correctly allowing for a 0.0015 to 0.005 in. (40 to 125 μm) clearance between the two surfaces at the braze material flow temperature to allow for capillary action and joint wetting.

- Clean the surfaces of the joint materials.

- Apply flux to both pieces.

- Fixture the two pieces together with a braze ring or perform the position in the coil.

- Heat the parts until both pieces achieve the braze material flow temperature then stick feed the braze material if preforms are not being used.

- Clean the brazed joint to remove all of the flux residues.

You can also watch some videos on how to induction braze condenser evaporator connections¹ or condenser copper tubes with handheld induction heating systems.

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