This article begins with a discussion on the principle of induction brazing and addresses applications, advantages, and limitations of the process. It provides information on the induction brazing equipment and solid-state induction generators that are used in induction brazing. The article illustrates several basic joint designs for induction brazing as well as typical coils and some frequent applications and lists joint parameters for parts which are to be brazed by induction heating. It concludes with a discussion on the effect of thermal expansion on stress in the joint.

This article focuses on the process design set-up procedure for brazing and soldering. It provides a detailed account of the types of base metals that can be joined by these processes, and reviews the factors to be considered to enhance the joint design. Criteria for selection of the right induction heating equipment to carry out the brazing or soldering operation are also provided. The article describes the types of brazing filler metals and joint designs. It also presents the types of inspection methods, namely, mechanical and visual, used to determine the quality of the brazed joint. Important considerations for the automation of induction-heated brazing applications are also discussed. The article concludes by emphasizing the need for documenting an in-control process which is a vitally important reference for questions or problems arising in the machine settings or part quality.

This article provides information about the selection of brazing processes and filler metals and describes the brazing (heating) methods, including manual torch brazing, furnace brazing, induction brazing, dip brazing, resistance brazing and specialized brazing processes such as diffusion and exothermic brazing. The article explains joint design, filler materials, fuel gases, equipment, and fluxes in the brazing methods. The article also describes the brazing of steels, stainless steels, cast irons, heat-resistant alloys, aluminum alloys, copper and copper alloys, and titanium and titanium alloys.

Controlled atmosphere chambers are used to control the surface chemistry of the metals that are being processed. This article focuses on the various types of controlled atmospheres used in induction heat treating and brazing, namely, inert gas atmospheres based on argon and helium; prepared and commercial nitrogen-base atmospheres; and brazing atmospheres. It provides detailed information on two types of controlled atmosphere chambers: atmosphere and vacuum. The article also describes the selection factors, advantages, and disadvantages of these chambers.

Brazing and soldering are done at temperatures below the solidus temperature of the base material but high enough to melt the filler metal and allow the liquid filler metal to wet the surface and spread into the joint gap by capillary action. This article discusses the common advantages of both brazing and soldering. It describes the brazing and soldering of cast irons, as well as the selection of brazing filler material. The article discusses various brazing methods: torch brazing, induction brazing, salt-bath brazing, and furnace brazing. It concludes with information on the application examples of brazing of cast iron.

Cast irons and carbon steels are brazeable materials, although the brazeability of cast iron is lower than that of carbon steel. The article provides a detailed discussion on the brazeability of different types of cast iron (malleable iron, ductile iron, and gray iron), carbon steels, and dissimilar metals. It describes the factors considered in the selection of filler-metal for cast iron and carbon steel brazing, such as temperature and environment, brazed joint design, heat source, and heat-treatment requirements. The article also discusses the basic considerations in cleaning and fixturing procedures, filler metal and flux/atmosphere feeding procedures, and the heating methods of cast iron and carbon steel brazing.

Copper, copper alloys, and precious metals are probably the most easily brazed metals because of their resistance to oxidation at high temperatures. This article provides a brief discussion on the metallurgy of copper, copper alloys, and precious metals and discusses the filler metals, brazing fluxes, joint clearance and design, and different brazing processes used in brazing of copper, copper alloys, and precious metals.

The quality of brazed stainless steel joints depends on the selection of the brazing process, process temperature, filler metal, and the type of protective atmosphere or flux. This article provides a detailed discussion on the applicability and brazeability of stainless steel and lays an emphasis on the selection of suitable filler metal, brazing processes, and its corresponding furnace atmosphere for brazing different grades of stainless steel. The types of brazing processes include torch brazing, furnace brazing in different atmospheres (dissociated ammonia, dry hydrogen, and vacuum atmosphere), dip brazing in salt bath, and high-energy-beam brazing. A complete list of the typical compositions and properties of standard brazing filler metals for brazing stainless steel is also provided.

Electromagnetic induction is a way to heat electrically conductive materials such as metals. This article provides a brief history of electromagnetic induction and the development of induction heating technology. It explores various applications such as heating prior to metalworking, heat treating, melting, joining (welding, brazing/soldering, and shrink fitting), coating, paint curing, adhesive bonding, and zone refining of semiconductors. The article also discusses the advantages of induction heating.

This article provides a discussion on filler metal selection, brazing procedures, and brazing equipment for brazing refractory metals. These include molybdenum, tungsten, niobium, and tantalum, and reactive metals. Commercially pure and alpha titanium alloys, alpha-beta alloys, zirconium alloys, and beryllium alloys are some reactive metals discussed in the article.

This article describes the physical principles of brazing with illustrations and details elements of the brazing process. The elements of brazing process include filler-metal flow, base-metal characteristics, filler-metal characteristics, surface preparation, joint design and clearance, temperature and time, rate and source of heating, and protection by an atmosphere or flux. The article explains the different types of brazing processes: manual torch brazing, furnace brazing, induction brazing, dip brazing, resistance brazing, infrared (quartz) brazing, exothermic brazing, electron-beam and laser brazing, microwave brazing, and braze welding.

This article presents an introduction to brazing, including information on its mechanics, advantages, and limitations. It reviews soldering with emphasis on chronology, solder metals, and flux technology. The article also provides useful information on mass, wave, and drag soldering. It presents a table which contains information on the comparison of soldering, brazing, and welding.

This article discusses the principles of operation, equipment needed, applications, and advantages and disadvantages of various fusion welding processes, namely, oxyfuel gas welding, electron beam welding, stud welding, laser beam welding, percussion welding, high-frequency welding, and thermite welding.

This article is a compilation of best practices, materials, and techniques for the design and manufacture of modern induction forge coils. It presents the basics of induction coil design along with various design considerations, namely, copper tube selection, water flow considerations, and brazing and fabricating the copper coil winding for heating billets, bars, and slabs. The article describes refractory selection criteria and the methods of mounting and securing the induction coil winding, and presents general refractory installation guidelines for induction heating applications. It provides information on curing, form removal, dryout, and coil refractory seasoning. Wear rails that are designed to prevent damage to the coil refractory and subsequent coil winding are also discussed. The article concludes with a discussion on preventive maintenance practices for induction forging coils.

This article focuses on the frequently encountered causes of induction coil failures and typical failure modes in fabrication of hardening inductors, tooth-by-tooth gear-hardening inductors, clamshell inductors, contactless inductors, split-return inductors, butterfly inductors, and inductors for heating internal surfaces. It discusses the current density distribution and the skin effect, the proximity effect, and crack-propagation specifics. The article also describes selected properties of copper alloys, the electromagnetic edge effect of coil copper turn, and the effect of magnetic flux concentrators on coil life. It also reviews the importance of having appropriate and reliable electrical contacts.

This article describes the dip brazing process and the principal types of furnaces used for molten-salt-bath dip-brazing applications. It provides information on equipment maintenance, which is divided into temperature control, control of the liquid, and maintenance of the vessel. The article presents the typical salts used for molten-salt dip brazing of carbon and low-alloy steels with selected filler metals in tabular form. It concludes with information on dip brazing of stainless steels, cast irons, and aluminum alloys and safety precautions of the process.

This article outlines the requirements and methods associated with the inspection of brazements. It emphasizes the incorporation of these requirements into the overall quality system. The article reviews the acceptance limits, design limitations, and nondestructive and destructive inspection techniques involved in the brazement inspection. Selected case studies are also provided for further reference.

This article provides information on single-shot and scanning, the two types of induction heat treating processes that are based on whether the induction coil is moving relative to the part during the heating process. It describes the effect of the frequency of induction heating current on the induction coil and process design, and the control of heating in different areas of the inductor part. The article reviews three main tools for adjustment of coil design and fabrication: coupling gap, coil copper profile, and magnetic flux controllers. It examines the method of holding a part and presenting it to the inductor during the initial inductor design. The article provides information on coil leads/busswork and contacts that mechanically and electrically connect the induction coil head to the power supply. It concludes with a discussion on flux and oxide removal, leak and flow checking, silver plating, and electrical parameter measurement.

Brazing technology is continually advancing for a variety of metals including aluminum and its alloys and nonmetals. This article discusses the key physical phenomena in aluminum brazing and the materials for aluminum brazing, including base metals, filler metals, brazing sheet, and brazing flux. It describes various aluminum brazing methods, such as furnace, vacuum, dip, and torch brazing. Friction, flow, induction, resistance, and diffusion brazing are some alternate brazing methods discussed. The article reviews the brazing of aluminum to ferrous alloys, aluminum to copper, and aluminum to other nonferrous metals. It also discusses post-braze processes in terms of post-braze heat treatment and finishing. The article concludes with information on the safety precautions considered in brazing aluminum alloys.

This article presents an overview of resistance brazing (RB) used for many applications involving small workpieces, for small joints that are part of very large equipment, or for low-volume production runs. It lists the advantages and limitations of RB and outlines the factors that contribute to high quality in an RB joint. The article discusses the classification of RB such as manual RB or automatic RB. It describes the selection of metal electrodes and filler metals for RB. The filler metals include silver alloys, aluminum-silicon alloys, and copper-phosphorus alloys.