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.
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.
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.
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.
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.
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.
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|
|Type of Process||Non-Contact||Contact Process|
|Is Heat Contained?||Yes||No|
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.