Brazing & Soldering Automation C o p p e r, b ra s s, s t e e l , s t a i n l e s s, c a r b i d e, a l u m i n u m — a ny b a s e metal combination is a candidate fo r t h e F u s i o n P ro c e s s. Alloys Applicators Machines 4658 East 355th Street, Willoughby, Ohio 44094 Phone (800) 626-9501, (440) 946-3300 Fax (440) 942-9083 Web: www.fusion-inc.com E-Mail: info@fusion-inc.com North American Sales Offices Chicago • Cincinnati • Dallas • Detroit • Los Angeles New York • Rochester • Tampa • Calexico, CA Mexico City, Mexico • Monterrey, Mexico • Toronto, Canada Overseas Sales Locations Korea • Hong Kong • Japan • South Africa • Israel The Netherlands • United Kingdom • Spain • Sweden Switzerland • Australia • Denmark • Eastern Europe Turkey • France • Italy • Germany • Taiwan People’s Republic of China Subsidiaries Fusion Automation, Inc. Harlow, England Phone (44) 1279 443122 Fax (44) 1279 4 24057 E-Mail: salesuk@fai-uk.com Fusion Automation Japan Tokyo, Japan Phone (81) 4 2709 5223 Fax (81) 4 2709 5224 E-Mail: rrai@fusion-inc.com Bulletin T-101/ENG © 2003 Fusion, Inc. All Rights Reserved Printed in U.S.A. The Fusion Process Au t o m a t i c d i s p e n s e r a p p l i e s p re m e a s u re d d e p o s i t s of F u s i o n Pa s t e A l l oy t o c o p p e r t u b e j o i n t s. For over 40 years, Fusion has been providing automation solutions for manufacturers engaged in production brazing and soldering. Fusion takes a Table of Contents process approach to automating your application. This process consists of three key ingredients: Paste The Fusion Process . . . . . . . . . . . 2–3 Alloys, Applicator Equipment, and Automatic Machines. Your operation will be transformed with Paste Brazing & Soldering Alloys. . . . . Applicator Systems . . . . . . . . . . . . . . 4 the overall goal of reducing metal joining costs P re c i s i o n h e a t p a t t e r n through increased productivity. f i l l e r m e t a l eve n l y With the Fusion Process, joint quality is virtually • Inventory is reduced since paste alloys adapt to joints regardless of size or dimension. guaranteed, due to the elimination of human error. Material costs are controlled, since filler metal and • Rotary Index Type. . . . . . . . . . 6–7 flux are applied in a single step—in just the right amount. Labor costs become insignificant, as one • Fixed Station Braze Mate . . . . 8–9 operator turns out hundreds of brazed or soldered assemblies per hour. Heating Concepts . . . . . . . . . 10–11 Paste Applicator Concepts . . . 12–13 • Single-step application of paste alloys means no separate fluxing is required. • Numerous filler metal/flux combinations are available to suit the specific needs of each application. 5 Automatic Machines Compare the Fusion Process with Your Brazing or Soldering Operation d i s t r i bu t e s b ra z i n g t h ro u g h o u t j o i n t a re a . • Absence of corrosive flux spray eliminates risks to equipment and personnel. • Elimination of human error improves joint quality. • Labor costs are reduced since typically, one unskilled operator is required to operate machine. • Fusion machines are generally amortized within 12–18 months. Ty p i c a l l y, F u s i o n M a c h i n e s a re “Total Responsibility” Philosophy. . . 14 designed to function with one o p e ra t o r m a n u a l l y Facilities. . . . . . . . . . . . . . . . . . . . . 15 loading and u n l o a d i n g p a r t s. 2 www.fusion-inc.com 3 Pa s t e Alloys Slide-mounted applicator g u n d e p o s i t s F u s i o n Pa s t e A l l oy t o a s s e m b l y j o i n t Fusion Paste Alloys deliver all the ingredients for a strong, void-free brazed or soldered joint in one deposit. Finely-atomized filler metal, proper flux and a neutral binder are blended into a homogeneous mixture. Upon heating, the liquid flux is released first, followed by the filler metal, which melts and flows into the joint area. By permitting automatic, measured dispensing and eliminating separate fluxing, paste alloys offer the optimum in joining economy, quality, and safety. Every batch of paste alloy is tested and analyzed to ensure it meets both Fusion standards and your specifications. Our Technical Services Group directs paste R & D by modifying existing formulations and developing new products. Standard Fusion Brazing & Soldering Alloys Filler Metal I n e r t g a s a t o m i z a t i o n p ro d u c e s f i l l e r Tin/Lead Phos/Copper Tin/Silver Copper Lead-Free Aluminum Silver Nickel Cadmium-Free Silver Gold a re a . Key to the efficient use of Fusion Paste Alloys is a Fusion Automatic Paste Applicator, which provides for fast, accurate, repeatable deposition of paste alloy to joints of virtually any size and shape. Pneumatically and electrically operated, the basic Fusion applicator control panel is accompanied by an applicator gun and reservoir. Paste stored in the pressurized reservoir is fed to the applicator gun, through the nozzle, and onto the parts in deposit sizes ranging from small dots to continuous stripes. Typically, a pneumatic cylinder positions the gun near the part, then retracts after paste application. A photo eye senses each properly fixtured part and ensures that the gun actuates only when paste alloy is required. Applicators can control one or several paste guns, and may be manually operated or integrated into an automatic machine through the PLC. (See pages 12-13 for a review of proven applicator concepts.) m e t a l s a l l oye d t o exa c t i n g s t a n d a rd s fo r Hand-held applicator gun dispenses paste automatically as dot o r s t r i p e d e p o s i t s. Applicator Systems Model 610 Applicator The Model 610 is designed to dispense small deposits of paste alloys. Uniform air pressure is introduced to a plastic cartridge, which serves as both paste reservoir and dispenser. Digital timer, programmable feature, footswitch and syringe stand included. Dimensions: 3.0”H x 11.75”W x 5.75”D. (76mm x 298mm x 146mm) c o m p o s i t i o n , m e l t i n g ra n g e, a n d Model 710 Applicator compatibility with base metals to be joined. I n g e n e ra l , F u s i o n f i l l e r m e t a l s c o n fo r m t o Designed for stand-alone, high volume use, the Model 710 controls one or more Fusion FE-Series guns. Adjustable time and pressure controls, quick-disconnects for hose attachment, and choice of limit switch or foot pedal actuation. Dimensions: 14.75”W x 5.75”D x 3.0”H. (375mm x 146mm x 76mm) (Note: Reservoir, stand and gun sold separately.) a l l a c c e p t e d i n d u s t r y s t a n d a rd s. F l u x i n g Ag e n t D e s i g n e d t o re m ove a n d p reve n t re - fo r m a t i o n of s u r fa c e ox i d e s d u r i n g h e a t i n g . Ty p e a n d a m o u n t a re c a re f u l l y m a t c h e d t o t h e s p e c i f i c application, ensuring dependable joints with m i n i m a l f l u x re s i d u e. V i s i t w w w. f u s i o n - i n c. c o m fo r s p e c s fo r M o d e l s 6 1 0 N e u t ra l B i n d e r a n d 7 1 0 A p p l i c a t o rs. Pa s t e - l i ke b i n d e r h o l d s f l u x a n d f i l l e r m e t a l i n s t a b l e s u s p e n s i o n ; p reve n t s f i l l e r m e t a l / f l u x i n t e ra c t i o n . C o n t ro l l e d c o n s i s t e n cy e n s u re s e r ro r - f re e a p p l i c a t i o n a n d 4 ke e p s p a s t e a l l oy l o c a l i z e d i n t h e j o i n t a re a . Filler Metal Fluxing Ag e n t N e u t ra l Binder www.fusion-inc.com 5 R o t a r y m a c h i n e c o n veys f i x t u re d p a r t s t h ro u g h b ra z i n g a l l oy a p p l i c a t i o n , h e a t i n g a n d c o o l i n g cyc l e s. Automatic Mach ines Custom built for your application, the Fusion Rotary Index 200 machine is widely used for high volume, automatic brazing and soldering applications. The typical machine sequence begins with manual or automatic loading of parts into stainless steel fixtures. Indexing clockwise, the parts are pasted by one or more automatic applicator guns. These guns, mounted on pneumatic slides, apply a premeasured deposit of paste alloy to each joint. Rotary Index 200 Dimensions: 48” x 48”, 72” x 72”, or 80”x 80” (1219mm x 1219mm, 1829mm x 1829mm, 2032mm x 2032mm) Stations: 8–24. Production Rate: 300–1,200 parts per hour. After pasting, the parts index again through a series of natural gas/air burners. The burners progressively heat the assembly to the liquidus temperature of the filler metal. Following heating, the part indexes through a series of cooling stations. Both air and water are used to solidify the alloy and bring the part and fixture back to room temperature. The finished part is then automatically ejected or manually unloaded by the operator. Although most Fusion machines employ open flame heat, alternative heat sources can be used. (See page 10.) 8-Station Brazing Machine Assembly: Three (3003) aluminum tubes to (6061) aluminum union block. Paste Filler Metal: Fusion NPA-1070-400, aluminum/silicon filler metal, corrosive flux. Production Rate: 300 parts per hour, one operator. Fusion machines c a n b e bu i l t t o Standard Features • Welded frame made of 4” x 4” x 1/4” wall steel tubing with a 3/4” thick Blanchard ground top plate • Machine frame is powder coated • Machine frame has adjustable legs for easy height adjustment, plus adjustable leveling feet for making fine adjustments. • Operator Station with PLC Interface makes part changes quick and easy with recipe function while providing machine diagnostics for quick troubleshooting • Gas Flowmeter and Manifold Manometer to verify process settings • Air and water cooling valve timers adjustable through Operator Interface and are unique to recipe code • Needle Valves installed on all air and water cooling outlets • Individual gas cocks installed for each burner to allow individual flow adjustments, or to turn burners on/off depending on part being run • Stainless steel tubing used for burner pattern provides rigidity • All utility connections located together • Color-coded piping for gas lines, air lines, and water lines • Air dump valve with lockout for main air supply • Lockable Electrical Panel Disconnect • Hi/Lo Heat System conserves fuel by switching to low settings when parts are not loaded • Isolation valves installed on incoming air and fuel source lines • Weiss Cam-Driven Indexer • 3/4” thick aluminum tooling plate • Stainless steel tooling plate cover • Stainless steel water trough • Safety pressure switches on heat system detect low gas pressure, high gas pressure, and low air pressure • Proximity switches installed on extend and retract positions of all slides • Flow Controls installed on all cylinders and slides • Air dump valves installed on all slides to assist with setups and adjustments • Paste tanks supplied with quick-release lid clamps • Paste guns controlled through the PLC to allow paste adjustment through the PLC recipe feature • Manual paste purge push buttons supplied for each paste gun • 1 spare paste gun supplied for each paste gun used • Free servicing of paste guns when Fusion paste products are used • Allen-Bradley* SLC 5/02 PLC with a DTAM Operator Interface • 24VDC control voltage • Quick Disconnects on proximity switches, pressure switches, and solenoid valves for simple maintenance * Alternative processors available upon request Rotary Index 100 Fusion’s Rotary Index 100 is a smaller-scale version of the Rotary 200 Machine. With a compact footprint of only 36”W x 48”D, this machine is ideal for relatively small assemblies. Sequence of Operation: • Operator loads assembly into stainless steel fixture. • Deposit of paste alloy is applied automatically (or manually) to the joint area. • Assembly indexes through a series of natural gas/air heat stations. • Compressed air and water quench cools both the part and fixture for safe operator unloading Dimensions: 36”W x 48”D x 38” load height (914mm x 1219mm x 965mm) Stations: 6 or 8 stations. Production Rate: 100–200 parts per hour depending on assembly mass and configuration. CE Certification. 12-Station Soldering Machine Assembly: Two-piece brass cover plate. Paste Filler Metal: Fusion PAD-165-852, low temperature solder, intermediate flux. 6 Production Rate: 450 parts per hour, one operator. w w w. f u s i o n - i n c . c o m 7 BrazeMate 100/150/200 Standard Features • Operator Station with PLC Interface makes part changes quick and easy while providing machine diagnostics for quick troubleshooting • Quick-Disconnect manifolds require no tools to change making part changeovers quick and easy • Fully adjustable manifold position makes machine configurable for most applications • Gas Flowmeter and Manifold Manometer to verify process settings • Heat, Air Cooling, and Water Cooling time adjustable through Operator Interface • Stainless steel tubing used for burner pattern provides rigidity • Guarding provides safety, process stability, and shielding from air currents • Banner® Two-Hand safety switches • All guard doors hinged for easy maintenance • Color-coded piping for gas lines, air lines, and water lines • Hi/Lo Heat System conserves fuel by switching to low settings between cycles • Oscillating Heat Slide with adjustable stroke distributes heat throughout the joint area evenly • Stainless steel Water Trough • Safety pressure switches on heat system detect low gas pressure, high gas pressure, and low air pressure • Proximity switches installed on extend and retract positions of all slides • Flow Controls installed on all cylinders and slides • Paste tanks supplied with quick-release lid clamps • Paste guns controlled through the PLC to allow paste adjustment through the PLC • 1 spare paste gun supplied for each paste gun used • Allen-Bradley* MicroLogix PLC with a MicroView Operator Interface • 24VDC control voltage • Quick Disconnect on proximity switches, pressure switches, and solenoid valves to make maintenance quick and simple. • Leveling Feet * Alternative processors available upon request ADDITIONAL BRAZEMATE 150/200 STANDARD FEATURES • Heat slides include rotating motion to swing heat pattern into position, while keeping the burners up and away from the operator • Overhead lighting keeps things visible for the operator ADDITIONAL BRAZEMATE 200 STANDARD FEATURES • Independent heat systems and heat manifold slides allow two completely different assemblies to be processed, or one assembly with multiple joints using different heat values 8 Fixed Station “Braze Mate” Braze Mate 200—Dual Station The Braze Mate 200 has dual, independently controlled heat stations so different assemblies can be brazed or soldered simultaneously. This machine is ideal for multiple joint assemblies that require “step” brazing. Operation sequence is nearly identical to Braze Mate 100. Dimensions: 72”W x 56”D x 34” load height (1829mm x 1422mm x 864mm) Three paste applicator modes: 1. Fully automatic, slide mounted, in-station. 2. Semi-automatic, fixed position, off-station. 3. Hand-held, automatic, in-station. Production Rate: 120 parts per hour typical. Braze Mate 100—Single Station The Braze Mate 100 is the ideal brazing/soldering machine for lower volume applications or short runs of various part styles. Heat slide with adjustable stroke oscillates throughout timed heat cycle to eliminate “hot spots” at the assembly joint area. Sequence of Operation: • Operator loads assembly into stainless steel fixture. • Paste applied (hand-held or slide-mounted) with automatic dispenser gun. • Dual, zero-pressure touch buttons depressed to actuate automatic, gas/air heating/cooling cycle. • Joined assembly unloaded by operator. O s c i l l a t i n g bu r n e rs d i s t r i bu t e h e a t eve n l y t h ro u g h o u t j o i n t a re a ; t i m e d a i r a n d wa t e r Dual heat stations sequence cools part f e a t u re i n d e p e n d e n t a n d f i x t u re fo r s a f e c o n t ro l a n d h i / l o f l a m e unloading. c o n t ro l t o c o n s e r ve fuel. Dimensions: 36”W x 48”D x 34” load height (914mm x 1219mm x 864mm) * Braze Mate 150 operates identical to the Model 100, however, is 72”W x 56”D to accommodate larger, multiple joint assemblies. Production Rate: 60 parts per hour typical. w w w. f u s i o n - i n c . c o m 9 Heating Concepts P re c i s e l y p o s i t i o n e d g a s / a i r bu r n e rs a re fo c u s e d o n c o p p e r a n d b ra s s va l ve a s s e m b l y j o i n t s. An important aspect of Fusion Brazing and Soldering Machines is their precise control of the heating function. Natural gas is the most common choice of fuels, with compressed air added to promote combustion. Propane, methane, or similar high-energy fuels can also be used. Where more intense heat is required, oxygen can replace compressed air. S i n g l e - a x i s ro b o t s p rov i d e t h e u l t i m a t e i n h e a t i n g f l ex i b i l i t y. Burner positions can b e e a s i l y c h a n g e d by Careful placement of gas/air burners ensures sound joints by bringing each part of the assembly to joining temperature at the same time—even when parts with different masses are being joined. Further refinement of the heating pattern can influence how the molten filler metal is distributed, either keeping it localized to fill a wide joint gap or coaxing it to penetrate deeply into tight-fitting areas. Depending on the application, Fusion employs a wide variety of heating methods. s e l e c t i n g s t o re d “ re c i p e s ” t h ro u g h t h e m a c h i n e P L C a n d Pa n e l V i ew I n t e r fa c e. R a d i a n t - t y p e, g a s / a i r h e a t p rov i d e s b ro a d , u n i fo r m c ove ra g e, i d e a l fo r m u l t i p l e, c l o s e l y - s p a c e d j o i n t s. R a p i d , l o c a l i z e d h e a t of an induction coil is i d e a l fo r a p p l i c a t i o n s w h e re f l a m e i s p ro h i b i t i ve. G a s / ox y g e n h e a t b r i n g s l a m p bu l b f e r r u l e j o i n t s to 1440°F liquidus temp e ra t u re of f i l l e r m e t a l . 10 w w w. f u s i o n - i n c . c o m 11 Paste Applicator Concepts As noted earlier, an important feature of Fusion Paste Alloys is their adaptability to various joint configurations. In most cases, a single dot of paste is applied to the joint area for distribution during heating by natural forces of capillary attraction. More complex parts may require several dots, a stripe, or an intricate combination of the two before parts are loaded onto the primary brazing or soldering machine. Dual station pasting sys t e m u t i l i z e s s i m p l e, m o t o r - d r i ve n s p i n d l e s to apply 360° stripe d e p o s i t t o b ra s s c o m p o - S i n g l e - a x i s ro b o t g u i d e s applicator gun to d i s p e n s e p a s t e a l l oy t o t u b e j o i n t s. 16A Single-Axis Robot For applications with multiple joints— spaced at different intervals on the same axis‚ Fusion guns can be mounted to a single-axis robot. This servo-driven device guides the gun across the entire component length, depositing paste at programmed points. Program “recipes”, stored in the PLC, are easily called up to changeover between virtually an unlimited number of part styles. nent at 300 per hour Satellite Paste Applicators Multi-Axis Robot For intricate and complex joint designs, Fusion applicator guns can be mounted to a multi-axis robot. The paste pattern is programmable to accommodate future product design changes. With a hand-held teach pendant, the robot is capable of storing up to 99 different programs. Safety features on this system includes sliding, polycarbonate guards on three sides with interlock switches, and light curtain with E-stop function. ra t e. Designed to complement an existing heat source, such as furnace or induction. These free standing units apply single, multiple, or circular paste deposits onto components. Cycling is automatic, with an operator removing the pasted part, adding other components, and loading into the adjoining heat source. C o m p a c t sys t e m a p p l i e s s i x d e p o s i t s of c o p p e r paste simultaneously to s t e e l f u e l ra i l a s s e m b l y. A f t e r p a s t i n g , o p e ra t o r l o a d s a s s e m b l y onto furnace belt at 4 0 0 p e r h o u r. 12 R o b o t a p p l i e s n i c ke l p a s t e a l l oy a c c u ra t e l y a ro u n d t h e 3 7 t u b e bu n d l e. w w w. f u s i o n - i n c . c o m 13 C o r p o ra t e P ro t o t y p e t o o l i n g i s mounted on a lab machine to determine paste applicating method, heat pattern, a n d p ro d u c t i o n ra t e a c h i eva b l e. “Total Responsibility” Philosophy Fe a s i b i l i t y t e s t i n g p a ra m e t e rs a re d e s i g n e d into the final machine p ro d u c t i o n f i x t u re t o m a i n t a i n b ra z e d / s o l d e re d a s s e m b l y s p e c i f i c a t i o n s. H e a d q u a r t e rs The obvious compatibility of paste alloys and automation prompted formation of the Fusion Machine Division over 40 years ago. Today, this capable team is devoted to the design and fabrication of equipment for production brazing and soldering. Throughout this time, Fusion’s guiding hand has been its philosophy of “Total Responsibility”. Under this ideal, Fusion provides all that is necessary to successfully automate your metals joining operation—from paste alloys to applicators and automatic machines—and guarantees that they will work on the application. For applications with unusual requirements, we conduct formal Feasibility Testing Programs. Typically, a lab machine is equipped with prototype tooling for your assemblies. Important relationships between paste alloy application, heating, and cooling stations are observed under actual production conditions. Rates and performance data are verified through first-hand experience, and representative sample parts are produced for testing. Based on your input, refinements are made until the process and proposed equipment satisfy the most demanding production standards. With the data obtained from the feasibility study, the automatic machine is then built. A Fusion field service engineer then installs the machine in your plant and instructs your personnel on its operation. Direct factory service and personnel instruction is available for subsequent needs, as well as continued follow-up by your Fusion sales representative to ensure its proper operation for years to come. The result: Total Responsibility for your brazing or soldering operation from one, reliable source. W i l l o u g h by Plant No. 2 F u s i o n Au t o m a t i o n — England Facilities Corporate Headquarters: Willoughby, Ohio Located east of Cleveland, This 50,000 sq. ft. plant is home for Fusion’s sales and corporate offices and the Machine Division. In addition, Fusion’s Technical Services Group maintains laboratories here, providing constant input on the chemical and metallurgical aspects of metals joining. New customer applications are placed under the supervision of a professional project team which coordinates these resources for your benefit. Willoughby Plant No. 2 has 40,000 sq. ft. devoted exclusively to the production of paste alloys. Operations include a modern, nonferrous facility where pure metals are alloyed and atomized into a wide variety of filler metal powders. These powders are blended with chemical formulations to achieve the dual properties of single-step application and built-in fluxing so popular with Fusion paste alloy users. Fusion Automation Inc., a subsidiary based in Harlow, England also has metal powder and paste manufacturing capability. They coordinate a large network of distributors which brings Fusion paste alloys, applicators, and machines to metalworking manufacturers worldwide. Fusion is committed to providing the highest quality products and service in the brazing and soldering industry. How can the Fusion Process work for you? Contact us today and we will conduct a no-obligation analysis of your current operation. Service technician i n s t a l l s b ra z i n g machine and instructs p e rs o n n e l i n yo u r p l a n t . 14 w w w. f u s i o n - i n c . c o m 15