Induction Brazing vs. Flame Brazing is one of the most debated topics among industrial manufacturers. Some argue that Induction Brazing is costly and gets the job done quicker, while others say that Flame Brazing is more cost-effective and still produces quality results.

If you are confused and don’t know which method to go for, this article may help. We will discuss the differences between induction brazing and flame brazing, as well as their respective advantages and disadvantages. This way, you can easily decide which method suits your needs!

Induction Brazing vs. Flame Brazing: 8 Key Differences

Induction Brazing and Flame Brazing are both effective methods for joining metal pieces together. However, manufacturing experts often debate the differences between these two techniques.

Let’s explore how these two metals joining processes are different.

1.     Heat Source

Suppose one asks you to differentiate between induction brazing. Then, you can mention one key difference, i.e., a heat source. In flame brazing, a torch, which is a combination of oxygen and fuel gas, is used to heat the metal pieces.

On the hand, induction brazing uses an electromagnetic field to generate heat. The setup is placed inside an induction coil, and a high-frequency current generates the magnetic field, causing eddy currents within the filler metal, ultimately heating it.

2.     Throughput

The throughput of these two processes is subjective. In some cases, it is lower for induction brazing, while flame brazing seems more productive in other cases.

For instance, it is easier to automate the process when induction brazing is involved in batch production of identical products. Moreover, more heat is transferred per square millimeter through induction since it is produced within the metal rather than on the surface.

However, individually, flame brazing complex parts is much more efficient since you can easily braze any joint through it.

3.     Process Efficiency

Induction brazing is a more efficient process than flame brazing. In the first case, electrical energy is converted into heat energy, while chemical energy is changed into heat energy in the second case.

Moreover, as the heat is contained in a specified area, most of it is utilized, and significantly less is wasted. Hence, the efficiency is much higher when induction is involved.

4.     Quality of Joint

Induction Brazing and Flame Brazing create strong bonds between two pieces of metal.

Induction brazing produces clean, precise joints with little to no distortion or flaws due to the high accuracy of the process and its minimal risk of overheating the metal pieces.

Flame brazing also produces quality joints. However, the quality of induction-brazed joints is better in some cases.

quality of induction brazing copper

5.     Eco-friendliness

In induction brazing, no combustion of gases is involved, so there are no fumes and waste. This makes it an eco-friendlier process than flame brazing.

6.     Controllability

In other brazing techniques, such as furnace brazing, the furnace must be lit and run continuously for days. Production cannot be initiated or stopped immediately. In comparison, we have that luxury when induction heaters are employed.

Also, the parameters of the induction brazing machine are customizable. We can set its heating time and temperature. So, the results are not affected by changing operators. On the other hand, flame brazing depends more on the operator’s experience, and we cannot precisely set any parameters.

7.     Safety

In terms of safety, the induction brazing process is much safer since no physical contact of the workpiece with the heat source is involved. The technician can safely operate the brazing machine from a safe distance.

In the case of flame brazing, the flame needs to be directly in contact with the filler metal. Therefore, extreme caution is required when handling the torch.

8.     Cost

The initial setup cost of an induction brazing setup is higher than flame brazing. However, it suits your industry when bulk production is required. In contrast, a flame brazing setup is cheaper and is primarily utilized in small-scale applications.

9.     Portability

People often think that induction brazing machines are heavy and cannot be carried like gas cylinders, like in the case of flame brazing. However, that’s not true. Induction brazing machines are also available in portable options. For instance, FOCO’s portable induction brazing machine is lightweight, and you can safely carry it anywhere.

Table 1-Summarized View: Induction Brazing vs. Flame Brazing

Item Induction Brazing Flame Brazing
Heat Source Electromagnetic induction Flame/Torch
Process Throughput Less (Subjective) More
Setup Cost High Low
Type of Process Non-Contact Contact Process
Is Heat Contained? Yes No
Produces Fumes? No Yes
Controllable? Yes No
Portable? Yes Yes

Conclusion

Brazing is one of the most employed processes in the manufacturing industry. However, with multiple types available, it can be challenging for manufacturers to choose the right one for their needs.

We recommend using traditional flame brazing for a small-scale setup since the setup is affordable. However, many industries are shifting towards induction brazing for large-scale commercial applications. In short, induction brazing is a viable and more modern approach.

With induction, metal gets heated from the inside, resulting in faster throughput, better quality, product consistency, controllable production, and enhanced safety. Additionally, it also suits the environment since no combustion takes place. Hence, no fumes are produced.

At FOCO, we design multiple brazing machines for different industrial needs. So, consider our Induction Brazing solutions if you’re looking for a reliable, consistent, and fast method to join metals.