This chapter provides an introduction to induction soldering. It also illustrates the classification of the different soldering processes according to the heat source, as described in the German standard, Soldering: Categorization of Processes According to Energy Sources, Process Descriptions.

This chapter describes important aspects of the interrelationship between the workpiece and the inductor coil, an understanding of which is essential for achieving an efficient soldering process and a solder joint with the desired performance and reliability. It also discusses induction soldering machine operation parameters, including temperature measurement and control sensors. The chapter illustrates the equipment used in a fully automated induction heating system. Fully automated soldering systems include temperature monitoring devices to control the temperature-time profile, the movement of workpieces, the supply of solder filler metal and flux, and the provision of shielding gas in the solder joint area.

This chapter describes the general hazards of induction heating and the hazards that are specific to induction joining processes. It also includes a brief discussion of economic considerations in the use of induction soldering.

This chapter details various induction soldering processes, including soldering with manually fed solder, soldering with filler metal (preplaced) preforms, soldering with solder coating, and soldering with an automated solder wire feeder.

This appendix presents the United States, German and European soldering and brazing standard specifications.

This chapter presents the following groupings of metals and alloys that are soldered together: steel and iron-base alloys, aluminum and aluminum alloys, and copper and copper alloys. It also presents the ancillary materials and process methods that assist the solder filler metal in completing the solder joint through induction heating. The chapter focuses on the selection of fluxes and the use of inert gases or even vacuum to realize an oxide-free base material surface both before and during the soldering process.

This chapter explains the fundamentals of soldering technology and provides an overview of the soldering process. It discusses the wetting of the molten solder filler metal to the base material surface and the design aspects when induction heating is used to make the solder joint.

This chapter discusses the critical soldering faults that lead to quality degradation and potential failure of a soldered connection. It then describes the types of nondestructive evaluations used to inspect soldered and brazed joints, including dimensional and visual inspection, ultrasonic testing, radiographic examination, dye penetrant inspection, and leak testing, including overpressure tests. The chapter also provides an overview of destructive physical analysis.

This chapter focuses on factors that influence the mechanical properties of a soldered joint, including solder material, base material, solder joint design, soldering surface, soldering temperature, and test methodology.

This chapter provides a discussion on the power supplies of modern induction heating plants. It describes the mode of operation and functional principle of an inverter. The chapter also provides a short note on generator cooling, which is required for the components of the induction power supply. It then presents an overview of induction heating systems.

This chapter presents a brief review of the history of brazing and soldering. It illustrates complicated soldering techniques and masterful goldsmith work, as demonstrated by the famous gold mask of the Egyptian Pharaoh Tutankhamun. The chapter includes the image of a painting from Egypt circa 1475 B.C. that shows a goldsmith soldering with a blowpipe. Numerous similar images have been found in the tombs of ancient Egypt that offer insight into the practices of gold workers from the period, including the use of processes such as smelting, forging, and joining with both brazing and soldering.

This chapter presents guidelines that should be considered when designing inductor coils. It provides a detailed description of typical inductor coil shapes, including outer and inner field inductors, single-turn and multi-turn inductors, pancake inductors, hairpin inductors, double-hairpin inductors, channel or slot inductors, fork inductors, spoon inductors, powerline inductors, magnetic field concentrators, multiple inductors, folding inductors, and shielding gas inductors. The chapter provides an overview of inductor tube dimensions and inductor coil positioning. It also describes the design and fabrication of inductor coils.