Induction Heating Silicon Carbide for plasma research

To generate plasma, we apply an electrical field to a gas, with the goal of removing electrons from their nuclei.  These free-flowing electrons give the plasma key properties, including its electrical conductivity, a magnetic field, and sensitivity to external electromagnetic fields.

In this application test, the customer provided sample parts to be induction heated.  Ultraflex demonstrated the ability of the UPT-SB High Frequency Induction system to heat the stainless steel cup to 2700-2800⁰F within three minutes.  This demonstrated the feasibility of the system for Induction Heating Silicon Carbide for plasma research.

EquipmentUltraheat UPT-SB Megahertz Induction Heating System

Materials
• Silicon Carbide cylinder, with 1.22” OD and 0.5” ID

Key ParametersTemperature: 2700-2800⁰F
Power: 1 kW
Time: 180 seconds
Frequency: 1 MHz

Process:

1. The silicon carbide cylinder was centered in a single turn coil.
2. The UPT-SB3, which operates up to 1 MHz was turned on.
3. The part was heated to approximately 2700-2800^oF in 180 seconds.  This demonstrated the feasibility of this system for Induction Heating Silicon Carbide for plasma research.

Results/Benefits:

• Precise control of the time and temperature
• Power on demand with rapid heat cycles
• Repeatable process, not operator dependent
• Safe heating with no open flames
• Energy efficient heating

Pictures

Silicon Carbide Cylinder

Slilcon Carbide Cylinder heated to 2700-2800 F with 1 MHz Induction.

Slilcon Carbide Cylinder heated to 2700-2800 F with 1 MHz Induction.

Induction Heating SS cup for plasma research

To generate plasma, we apply an electrical field to a gas, with the goal of removing electrons from their nuclei.  These free-flowing electrons give the plasma key properties, including its electrical conductivity, a magnetic field, and sensitivity to external electromagnetic fields.

In this application test, the customer provided sample parts to be induction heated.  Ultraflex needed to demonstrate the feasibility of the UPT-S5 kW system for Induction Heating SS cup for plasma research, by heating the cup to 1350 – 1400 ⁰F within three minutes.

Stainless Steel Cup used for Plasma Research testing in the UPT-S5 Induction Heating System.

EquipmentUltraheat UPT-S5 Power Supply
HS-4 Heat Station

Materials
• Stainless steel cup – 1.854” OD, ID – .570”

Key ParametersTemperature: 1350 – 1400⁰F
Power: 2 kW
Time: 180 seconds
Frequency: 55 kHz

Process:

1. The cap assembly was placed up into the coil from the bottom turn, with 3” set in the long coil (6.250”).
2. This test demonstrated the feasibility of the system for Induction Heating SS cup for plasma research, by heating to an approximate 1350-1400⁰F within three minutes.

Results/Benefits:

• Precise control of the time and temperature
• Power on demand with rapid heat cycles
• Repeatable process, not operator dependent
• Safe heating with no open flames
• Energy efficient heating

Pictures

Stainless Steel Cup used for Plasma Research Testing

Stainless Steel Cup used for Plasma Research Testing

Braze brass barb fittings into brass housing

The customer currently outsources the process to braze brass fittings into the brass housing.  The cost of this outside processing is $30 per part.  By in-sourcing, the part cost will be reduced, and the customer can also avoid delays in the outsourcing process.

Equipment

Ultraheat UPT-S2 Power Supply
HS-4 Heat Station

Materials
• Silver brazing preform.
• Stay-Silv brazing flux

Key Parameters
Temperature: approximately 677°C
Power: 1.98 kW
Time: 150 seconds

Frequency
71 kHz

Process:

1. Braze Brass Fittings into Brass Housing: the barb fittings are positioned into the housing, with a pre-form placed at the position of the joint.
2. The assembly is then positioned into the induction coil.
3. At approximately 2:15, a small amount of brazing alloy is added by hand during the heating, to fill the opening not covered by the preform.  A production preform would completely encircle the part, and not have a gap.
4. The finished braze, shows a consistent fillet at the braze joint.

Results/Benefits:

Enables in-sourcing of an assembly process that has been done by a supplier.  Avoids costly delays in processing.

• Precise control of the time and temperature
• Power on demand with rapid heat cycles
• Repeatable process, not operator dependent
• Safe heating with no open flames
• Energy efficient heating

Pictures

Braze Brass Fittings into a Brass Housing: the barb fittings are positioned into the housing, with a preform placed at the position of the joint.  The assembly is then positioned into the induction coil.

After approximately 30 seconds.

After approximately 1 minute.

After approximately 90 seconds.

After approximately 2 minutes.  We see a small gap not covered by the preform.

After approximately 2:15.  A small amount of brazing alloy is added by hand during the heating, to fill the small gap not covered by the preform.

The finished braze after 2:30, shows a consistent fillet at the braze joint.

Videos

CONTACT!

Do you have a heating application?  Contact Ultraflex Power Technologies.  Ultraflex can provide a custom induction heating solution to meet your application and manufacturing requirements.  

Brazing a Heat Exchanger

The customer’s application is Brazing a Heat Exchanger.  There are “U” returns that are brazed to the receiving tubes on the heat exchanger.  These returns are used to flow the water through the heat exchanger, and keep the unit cooled.  Brazing tests were conducted with flux and without flux at the customer’s request.  The current process is done with a torch.

EquipmentUltraheat UPT-S5 Power Supply
HS-4 Heat Station

Materials
• Brazing preform
• Brazing flux (Test 1 only)

Key Parameters
Key Parameters
Temperature: approximately 1400-1450°F
Power: 2.35 kW
Time: 35 seconds for the first part. Slightly less time for subsequent parts, as heat is retained.

Frequency
145 kHz

Process:

1. For Test 1, we pre-coated the U return braze ring and receiving tube with white braze flux; then assembled the heat exchange unit with 13 U returns. (One set of tubes was left open for the customer to pressure test the assembly).  For Test 2, the unit was assembled without flux.
2. By moving the coil and heat station up/down, the assembly was moved in position to braze the components together.
3. We placed a copper shield “comb” under four receiving tubes to shield the plated carbon steel plate from the RF Field and heated the section to flow the phosphor bronze alloy pre-formed rings to braze on both sides of the U-bend simultaneously.
4. Heat time for the initial braze was recorded at 35 seconds – subsequent brazes required less time as the unit retains some heat following each cycle.

Results/Benefits:

Enables in-sourcing of an assembly process that has been done by a supplier.  Avoids costly delays in processing.

• Precise control of the time and temperature
• Power on demand with rapid heat cycles
• Repeatable process, not operator dependent
• Safe heating with no open flames
• Energy efficient heating

Pictures

Brazing a Heat Exchanger.  Test 1 (with flux): Flux is applied to the Heat Exchanger receiving tubes.

Brazing a Heat Exchanger.  Test 1 (with flux): Flux is applied to the "U"-shaped returns.

Brazing a Heat Exchanger.  Test 1 (with flux): "U"-shaped returns are assembled to the receiving tubes.

Brazing a Heat Exchanger.  Test 1 (with flux): A protective shield was placed around the area to be brazed.  This rudimentary shield provided some protection to the plate.  In a final production unit, the plate will be water-cooled.

Brazing a Heat Exchanger.  Test 1 (with flux): We braze each shaped return.  Brazing takes approximately 35 seconds per return.

Brazing a Heat Exchanger.  Test 1 (with flux): A completed braze.

Brazing a Heat Exchanger.  Test 1 (with flux): A completed braze.

Brazing a Heat Exchanger.  Test 2 (without flux): The customer also requested brazing samples without flux.

Brazing a Heat Exchanger.  Test 2 (without flux): Some completed and in-process brazes.

Brazing a Heat Exchanger.  Test 2 (without flux): The final braze on the heat exchanger is started.

Pictures

Brazing without flux:

Brazing with flux:

Induction Heating Mesh Tube for Plasma Research

To generate plasma, we apply an electrical field to a gas, with the goal of removing electrons from their nuclei.  These free-flowing electrons give the plasma key properties, including its electrical conductivity, a magnetic field, and sensitivity to external electromagnetic fields.

In this application test, the customer provided sample parts to be induction heated.  Ultraflex demonstrated the ability of the UPT-S5 5 kW Induction system to heat the stainless steel mesh tube to 1700⁰F within one minute.  The test of Induction Heating Mesh Tube for Plasma Research validated the use of this system for the customer.  

Mesh Tube tested with UPT-S5 Induction Heating System for Plasma Research.

Equipment

Ultraheat UPT-S5 Power Supply
HS-4 Heat Station

Materials
• Stainless Steel Mesh tube 2.2” OD, 0.020” wall thickness

Key ParametersTemperature: 1700⁰F
Power: 2.8 kW
Time: 39 seconds
Frequency: 65 kHz

Process:

1. The stainless steel mesh tube was centered in the coil and painted with 1500⁰F and 1700⁰F tempilaq indication paint.
2. The UPT-S5 was turned on, and a length of 4” was heated to over 1700⁰F in 38 seconds. By successfully Induction Heating mesh tube for Plasma Research, the customer was satisfied that the UPT-S5 would meet his requirements.

Results/Benefits:

• Precise control of the time and temperature
• Power on demand with rapid heat cycles
• Repeatable process, not operator dependent
• Safe heating with no open flames
• Energy efficient heating

Pictures

Mesh Tube used for Heating

Induction Heating SS Tube for Plasma Research

To generate plasma, we apply an electrical field to a gas, with the goal of removing electrons from their nuclei.  These free-flowing electrons give the plasma key properties, including its electrical conductivity, a magnetic field, and sensitivity to external electromagnetic fields.

In this application test, the customer provided sample parts to be induction heated.  Ultraflex demonstrated the ability of the UPT-S5 kW Induction system to heat the stainless steel tube to 1700⁰F within one minute.  This successful application test for Induction Heating SS Tube for Plasma Research, validated the customer’s use of the system for his testing.

EquipmentUltraheat UPT-S5 Power Supply
HS-4 Heat Station

Materials
• Stainless Steel tube 2” nominal OD 0.047” wall thickness

Key ParametersTemperature: 1700⁰F
Power: 4.2 kW
Time: 60 seconds
Frequency: 65 kHz

Process:

1. The stainless steel tube was centered in the coil and painted with 1500⁰F and 1700⁰F tempilaq indication paint.
2. The heat time for the UPT-S5 was set for 60 seconds.
3. A 5” length heated above 1500⁰F; and a 4” length heated over 1700⁰ This met the customer’s requirements for Induction Heating SS Tube for Plasma Research.
4. Uniform heat can be achieved by profiling the coil turns.

Results/Benefits:

• Precise control of the time and temperature
• Power on demand with rapid heat cycles
• Repeatable process, not operator dependent
• Safe heating with no open flames
• Energy efficient heating

Pictures

Soldering Copper Coaxial Cable with Copper Connectors

The objective of this application test is to determine heating times for soldering copper connectors onto a copper coaxial cable. The customer would like to replace hand soldering with soldering irons, with induction soldering. Hand soldering can be labor intensive, and the resulting solder joint is highly dependent on the skill of the operator. Induction soldering allows finite process control, and provides a consistent result.

Equipment

UltraHeat UPT-S2 Power Supply
HS-4 Heat Station

Materials

• Copper Coaxial Cable
• Plated copper connectors
• Copper bullet-shaped internal connector
• Copper pin-shaped internal connector
• Solder wire
• Carbon steel

Key Parameters

Test 1: Soldering Copper Coax Center Conductor to Bullet-Shaped Center Pin

Temperature: ~400F

Power: 1.32 kW

Time: 3 seconds for bullet connector

Frequency: 235 kHz

Key Parameters

Test 2: Soldering Copper Coax center conductor to Needle-Shaped Center Pin

Temperature: ~ 400F

Power: 1.32 kW

Time: 1.5 second for needle connector

Frequency: 235 kHz

Key Parameters

Test 3: Soldering Copper Coax to the End Connector (Bullet-Shaped Center Pin)

Temperature: ~ 400F

Power: 1.8 kW

Time: 30 seconds of heating time, followed by a 10 second cooling cycle

Frequency: 197 kHz

Key Parameters

Test 4: Soldering Copper 
Coax to the End
Connector
(Needle-Shaped Center Pin)

Temperature: ~ 400F

Power: 1.86 kW

Time: 30 seconds of
heating time, followed by a
10 second cooling cycle

Frequency: 199 kHz

Process:

For each type of center pin, the soldering process has two steps.  First, soldering the center pin (bullet-shaped or needle-shaped) to the center conductor of the coaxial cable; and second, soldering the coaxial cable with the pin into the end connector

Tests 1 and 2: Soldering copper coax center conductor to the connector center pin

1. The internal connector pin (needle and bullet followed the same process) were assembled to the coaxial cable center conductor. A solder slug roughly ½ the length of the pin where the wire is to be soldered, was cut and placed in the receiving end of the center pin. The copper conductor of the coax was positioned to rest on the solder slug in the pin with light pressure downward.
2. The assembly was placed into a two-turn induction coil, and power was turned on.
3. As the solder melted, the copper conductor of the coax seated into the center pin. The assembly was held still for several more seconds as the solder cooled. Note: it is important to keep the solder joint still until it has cooled. If movement occurs, a “cold” solder joint can result.

Tests 3 and 4: Soldering copper screw-type end connector to the Center Pin 

1. Solder wire was wound around the corrugated flutes of the coax. The coax with solder was placed into the end connector.
2. The assembly was placed into a u-shaped induction coil, and power was turned on.
3. Heat time – 30 seconds for either assembly followed by a 10 second hold to let the alloy solidify.

Results/Benefits:

The soldering was successful, and confirmed that induction is an excellent alternative to hand soldering.

• Precise control of the time and temperature
• Power on demand with rapid heat cycles
• Repeatable process, not operator dependent
• Safe heating with no open flames
• Energy efficient heating

Pictures

Components for the Bullet End Assembly

Components for the Needle End Assembly

Completed Solder Joints - Bullet End and Needle End to the Coax Center Conductor

Test 3: Solder is would around the corrugated coax.

Test 3: Assembled prior to solder cycle.

Finished assembly.

Videos

Test 1

Test 2

Test 3

Test 4

Ultraflex Power Technologies provides Induction Heating Solutions for your heating challenges. 

Contact us today about your heating application!

Melting Platinum with the UltraMelt 5P

The purpose of the application test was melting platinum, and to determine what quantities will melt effectively in the UltraMelt 5P.  

Due to its properties and high melting temperature, Platinum is a challenging metal to melt. The UltraMelt 5P is the ideal equipment for this task.

EquipmentUltraMelt 5P

Materials
• Scrap Platinum
• Crucible for melting
• A lid for the crucible
• Tongs
• Pipettes (for taking a sample in video 2)

Key Parameters of Test 1:
Melting Platinum – 250g of Scrap
Temperature: over 1768C
Power: 3.9 – 4.8 kW (power varied during the melting process)
Time: 4 minutes, 35 seconds
Frequency: 91 kHz

Key Parameters of Test 2:
Melting Platinum – 250g of solidTemperature: over 1768C
Power: 3.1 – 4 kW (power varied during the melting process)
Time: 4 minutes, 10 seconds
Frequency: 94 kHz

Process:

1. Platinum was added to the ceramic crucible.
2. UltraMelt 5P was turned on.
3. The engineer tapped lightly on the crucible to settle the material, and help the heat distribute throughout the material. The tapping also helped to loosen pieces of the scrap platinum to drop into the molten platinum.
4. A cap or lid was placed on the crucible to minimize heat loss. In this case, another crucible was used as the cap.
5. As power was applied, the platinum began to melt and flow to the bottom of the crucible.
6. There were some small differences in the process between test 1 and test 2, as noted in the videos.
   • For Test 1, with the Scrap Platinum, after 2 minutes 37 seconds of heating, the platinum is molten at the bottom of the crucible; After 4 minutes 35 seconds of operation, the platinum is completely molten, and the UltraMelt 5P is turned off.
   • For Test 2, with the solid piece of platinum, after 4 minutes 10 seconds of operation, the platinum was completely molten. A pipette was lowered into the molten platinum to take a sample.  The UltraMelt 5P was turned off.
7. Since we did not have a mold to pour the molten platinum into, we cooled the platinum in the crucible.  The crucible was turned upside down during cooling, to allow the platinum to eventually fall out of the crucible.

Results/Benefits:

Different quantities of platinum were tested in increments of 50g, from 50g to 250g.  The tests results indicated that successful platinum melting was optimized at approximately 250g.

Pictures

During the test, the engineer taps periodically on the crucible to help in the heating process.  The engineer is wearing welding goggles, due to the brightness of the molten platinum. 

Here we see the second crucible used as a lid for the primary crucible.

During test 2, a pipette was lowered into the molten platinum to take a sample.

When taking the sample, there was a brief flare.

A view of the still hot platinum in the bottom of the crucible.

After cooling, the platinum releases from the crucible.

The final melted piece of platinum after cooling.

The pipette with the cooled sample.

Videos

Test 1: Melting 250g of Scrap Platinum

Test 2: Melting a solid sample of platinum, and taking a sample

Ultraflex Power Technologies provides Induction Heating Solutions for your heating challenges. 

Contact us today about your heating application!

Brazing Carbide to Steel

Application Test Objective is Brazing Carbide to Steel, confirming the heating time.  Customer provided samples of carbide tips of various sizes and shapes to be brazed to a steel shanks of various sizes and shapes.  Confirm brazing feasibility and heating times using Ultraheat UPT-S5 5 kW for brazing carbide to steel.

Equipment

UltraHeat UPT-S5 Power Supply
HS-4 Heat Station

Materials

• Magnetic Steel Shanks
• Carbide Tips
• Alloy – EZ Flo 45 paste

Test 1 

Magnetic Steel Shank OD: 0.375”
Cone-Shaped Carbide Tip with taper from 0.5” OD to 0.062” at the peak

Key Parameters

Temperature: approximately 1450F
Power: 1.3 kW
Time: 35 seconds
Frequency: 115 kHz

Test 2 (See Video 1)

Magnetic Steel Shank OD: 0.250”
Spherical Carbide Tip with 0.638” diameter, and flat underside of 0.431”

Key Parameters

Temperature: approximately 1450F
Power: 1.5 kW
Time: 21 seconds
Frequency: 116 kHz

Test 3 (See Video 2)

Magnetic Steel Shank OD: 0.180”
Bullet-shaped Tip with major OD 0.264”

Key Parameters

Temperature: approximately 1450F
Power: 0.6 kW
Time: 13 seconds
Frequency: 114 kHz

Process for Brazing Carbide to Steel:

1. The magnetic steel shank and carbide were cleaned.
2. Paste alloy was added to the interface area between the shank and carbide.
3. Simple fixtures were used to hold the shaft in place, and hold the carbide in place.
4. Power was turned on, and the parts were monitored to confirm when the braze was complete.

Results:

All parts were brazed successfully, using the same coil and tap settings on the induction equipment. No equipment changeovers are necessary.

A formal fixture to ensure the parts are aligned during the brazing process is recommended.

Benefits:

• Precise control of the time and temperature
• Power on demand with rapid heat cycles
• Repeatable process, not operator dependent
• Safe heating with no open flames
• Energy efficient heating

Pictures

The completed brazed parts.

Video

Video 1

Video 2

Ultraflex Power Technologies provides Induction Heating Solutions for your heating challenges. 
Contact us today about your heating application.