Automatic Induction Brazing for Wear-resistant Plate

This automatic induction brazing system is specially developed for the brazing of wear-resistant plates, such as bimetallic composite plates, carbide-coated plates, and other hardfacing materials.

Using high-frequency induction heating, this solution ensures fast, uniform heating and strong metallurgical bonding at the joint surface—ideal for industries such as mining, construction machinery, metallurgy, and power generation.

Fully automated operation with programmable logic control (PLC) reduces labor intensity, increases joint consistency, and supports high-volume production.

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Automated Brazing Workflow

This section outlines the step-by-step brazing workflow for wear-resistant plates using Duolin's automated induction brazing equipment. The process is designed to ensure consistent joint quality, operational safety, and high production efficiency.

Automatic Loading

The wear-resistant plate (e.g., hardfacing composite or carbide-tipped steel) is automatically or semi-automatically loaded onto the fixture station.

A precision-guided clamping system holds the plate securely in place to ensure accurate alignment with the induction coil.

For batch processing, a servo-controlled or pneumatic loading arm can be integrated to handle continuous feeding and reduce manual labor.

Plate position is verified using optical sensors or limit switches for reliable repeatability.

Flux and Filler Application

A brazing alloy (in wire, paste, or shim form) is placed at the joint area where the wear plate connects with the base substrate or backing plate.

In some setups, a robotic dispenser or manual operator applies a consistent amount of flux and filler at pre-defined locations.

The alloy type and quantity are determined based on the joint gap, base materials (e.g., carbon steel, stainless, tungsten carbide), and operating temperature.

Correct filler placement is essential to achieve capillary flow during brazing and to avoid voids or cold joints.

Induction Heating

The workpiece moves into the C-shaped or channel-type induction coil, which delivers high-frequency electromagnetic energy to the joint area.

Induction heating raises the brazing zone to the required temperature (typically 600–1200°C) within seconds.

Duolin’s systems allow precise control of heating time, power level, and frequency for different part sizes and materials.

Optional infrared temperature sensors provide feedback to the PLC, enabling closed-loop control to maintain ideal heating profiles.

Brazing and Holding

Once the required temperature is reached, the brazing alloy melts and begins to flow between the surfaces via capillary action.

The holding phase ensures full alloy penetration and joint wetting.

The system maintains temperature for a defined soak period (e.g., 3–10 seconds) to allow full metallurgical bonding.

The induction power is then ramped down gradually to avoid thermal shock or joint distortion.

Brazed joints produced via induction typically offer superior strength and minimal oxide formation compared to torch brazing.

Cooling and Unloading

After the brazing cycle, the component is cooled using forced air or closed-loop water cooling, depending on the thermal mass and joint size.

Controlled cooling minimizes residual stress and ensures stable joint microstructure.

Once cooled to a safe handling temperature, the part is automatically released from the fixture and transferred to the next station (e.g., cleaning, inspection, or packaging).

For mass production setups, this stage can be fully integrated into a conveyor system or robotic cell for continuous flow.

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High-frequency brazing equipment is a new type of energy-saving and environmentally friendly induction heating equipment. It has the advantages of energy saving, good working environment and easy automation, and is widely used in various industries. 

Characteristics of induction brazing equipment

·Using solid-state inverter technology, integrated circuits and numerical control design, the equipment is energy-efficient, reliable and stable.Under the same conditions, it saves twice as much energy as ordinary welding equipment.

·The high-precision main control board is accurate and reliable, reducing the size deviation of the finished glasses plate and improving the accuracy and interchangeability of the glasses plate.

·The heating speed is fast and the welding is uniform, which can effectively reduce oxidation and decarburization, prevent or reduce welding deformation, thereby reducing man-hour consumption and improving production efficiency.

·The operation is simple, just place the glasses plate on the welding part. The successfully welded glasses plate is both beautiful and strong.

The whole automatic induction bonding system including the induction heating furnace,350KW induction heating equipment,PLC control station,glass plate transmission,air chiller.

Duolin, founded in 1994, is a trusted manufacturer of induction heating machines and solutions, with over 20 years of industry experience. Offering equipment with power ranges from 4-2000KW and frequencies from 0.5-400KHz, all products are designed by Duolin's expert engineering team and produced under strict ISO9001:2015 standards. As a high-tech enterprise, Duolin holds more than 20 national patents, providing energy-efficient and reliable induction heating systems for industries worldwide.

Duolin's induction heating solutions are widely used for applications such as carbon steel hot forging, gear shaft hardening, long bar heat treatment, pipe heating for hot bending, and non-ferrous metal heating like aluminum and copper. Since expanding internationally in 2007, Duolin has established agents in countries like Brazil, Germany, and India, with end users in over 15 countries, some of whom have been partners since 2009.

If any demand for induction heating for soldering or other industrial heating requirement,do not hesitate to contact Duolin induction.