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
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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
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