Translated Abstract
In industrial production, high-frequency induction brazing is widely used for its advantages, such as high heating speed, controlling shape with ease and automatic operation. The brazing temperature is the most important factor affecting the brazing quality. It directly relates to the brazing filler metal‘s wetting, spreading and filling. It also relates to the structure formation in each area of the workpiece. Therefore, in order to improve the quality of high-frequency induction brazing, it is necessary to study the temperature distribution in the process of induction brazing.Electrical contact with high-frequency induction welding has been studied. A finite element model of electrical contact with induction brazing has been established by ANSYS to compute the temperature distribution and variation of the workpiece, and then the accuracy of the simulation results are verified by an experiment. Meanwhile, we have studied the influence of temperature field on brazed quality from three aspects: the way of liquid brazing filler metal filling brazed gap, the brazed rate, the mechanical property of copper substrate. Finally, we have analyzed the problems existing in the process of brazing, and then two key technological parameters, the induction coil and heating methods, are optimized. The results showed that the brazing process parameters determine the temperature distribution, the higher of the frequency, the greater of the heating current, the lower of the coil height, then heating rate of temperature field is faster, final temperature is higher. The simulation results of high-frequency induction brazing are consistent with the actual temperature measurement results, the numerical results are accurate and reliable. ＂Quenching experiments＂ indicates the way of liquid brazing filler metal filling brazed gap largely depends on its temperature distribution. And with the increase of temperature, liquid brazing filler metal fills brazed gap in the manner of ＂from the fingertip to the root＂. The brazed rate of the electrical contacts increases with increase of brazing temperature, but when the temperature of faying face is all above the melting point, continues to rise brazing temperature has little influence on the brazed rate. The hardness of copper substrate after welding is significantly lower than before welding, decreased by about 50%. The temperature distribution of copper substrate has become more reasonable by using optimized induction brazing technics, is helpful to improve the brazing quality. And under the premise of that the brazing filler metal melt completely, the highest temperature of copper matrix is reduced about 200℃(reduced by about 20%), high temperature residence time is shortened about 2s(shortened by about 22%).
Translated Keyword
[high-frequency induction brazing numerical simulation temperature field process optimization]
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