Vacuum Brazing Furnace

Vacuum Branzing Furnace Manufacturer India

Laboratory Equipment Manufacturing

High precision, robust metal joints are produced using vacuum brazing furnaces, which are sophisticated metallurgical industry equipment. It is an improvement over the traditional methods as this process entails melting of filler metal at high temperatures while avoiding the melting of base materials. These advanced, compact furnaces for industrial applications in aerospace have a pumping system, power supplies and cooling systems for various heat treatment processes. It is expertize for Bionics Consortium Precision to perform vacuum brazing services in critical applications including aerospace industry, biomedicine and electronics where they are joining ceramic-to-metal and metal-to-metal assemblies. The company consists of highly experienced engineers who can choose suitable fixtures, joint designs, alloys, and processes for every application.

Manufacturer, Supplier and Exporter of Vacuum Brazing Furnaces in India

Bionics Consortium is a leading Indian company specializing in the design and production of high temperature vacuum brazing furnaces. Our brazing furnaces are employed in hundreds of applications throughout the manufacturing process across various industries. The praised accuracy, efficiency and control associated with brazing furnaces mean that these devices are indispensable when creating anything from intricate multi-joint assemblies to crucial turbine components used in renewable energies.

What Is Vacuum Brazing?

A furnace meant for vacuum brazing is an industrial machine that employs controlled vacuum environment to melt filler metals above 450°C so as to join metals together. Through capillary action bonding can then be achieved between base metals (ceramic like) and steel at temperature range 800°C-1150°C under vacuum atmosphere conditions. The furnace removes oxygen thus controlling oxidation while also heating fillers up to brazing temperature, hence making it ideal for joining materials which oxidize easily.

In the furnace-brazing process, dissimilar lower filler metal is used to form connections among metallic parts under controlled conditions within a high vacuum environment.

Vacuum brazing benefits

Environmentally friendly processes reduce pollution and improve corrosion resistance.
No need for expensive metal fluxes and no complex cleaning procedures.
A cleaner surface and higher yield are obtained in the process.
Durable furnace construction and fixtures save on maintenance costs.
Suitable materials consist of aluminum, copper, stainless steel, alloy steel, low carbon steel, titanium, nickel and Inconei.

Different Types of Vacuum Branzing Furnace

Vacuum brazing furnaces are available in various configurations and sizes, optimized for specific materials and processes, including high and low temperature applications, continuous operation, and special functions such as diffusion welding.

How Vacuum Brazing Works

To join two or more metals, filler metal in the form of powder, paste, or pre-formed alloy is placed at the junction areas inside a furnace during vacuum brazing. The high vacuum that is created in the furnace results from purging it of air and impurities. Oxidation that can weaken the joints is prevented due to the lack of oxygen. As a result, heating these parts to a temperature higher than the melting point of the filler metal but lower than that for the base metals creates a molten state where capillary action occurs before solidification.

Advantages of Vacuum Brazing for Joining Miscellaneous Materials

Choosing this method as an option for joining diverse materials has many benefits associated with it, such as:

Advanced Technology: It is one of the latest technologies applied in creating strong bonds between different types of materials through brazing. It requires skilled personnel who must have adequate knowledge about the selection of alloys as well as controlling heating rates so as to minimise distortion or stress during the cooling phase; furthermore, they use sophisticated brazing methods such as in-house metallising, plating, and glazing, as well as top-notch furnaces and leak testing equipment that create superior joints capable of withstanding severe conditions, ensuring that the assembled components pass the required tests in the anticipated environment.
Low cost: Vacuum brazing serves as a cost-effective technique that prevents oxidation and fouling of joint surfaces, thereby creating clean oxide-free joints. It eliminates the need for a middle layer between the original components, hence saving on material usage as well as process and labour expenses. Bionics Consortium Precision, being a service bureau, provides Design for Manufacturability (DFM) skills that will help optimise the prototyping stage by selecting suitable processes along with materials, hence achieving efficient manufacturing once full production begins.
Controlled Quality: Vacuum brazing is a very precise method that has strict control over quality during their execution, as they know what it takes to produce a good assembly every time. They follow regulations and are accredited with many bodies like AS9100D, ISO 9001, ITAR, and RoHS, as they always strive to maintain high standards.

Why select Bionics Consortium for a vacuum brazing furnace?

Assess the experience, equipment and expertise of a vacuum brazing service provider in order to guarantee successful implementation of advanced manufacturing processes.

Experience in vacuum brazing: Bionics Consortium is an experienced service provider offering vacuum brazing services to critical areas like aerospace, renewable energy and biomedicine. Through their services high performance, reliability and minimal oxidation ensuring demanding environments have been achieved by making high quality joints.
Certifications: Consider vacuum brazing providers with industry-relevant certifications such as Bionics Consortium which is ISO 9001:2015; ITAR registered; RoHS compliant; and use DFARS compliant metal components.
Materials: Before selecting a service provider, ensure they offer a variety of brazing materials and have the expertise to select the right parent materials and alloys for your application since each material has unique properties and limitations.
Communication capabilities: This implies that clear communication between parties partnering with a service provider is necessary where their roles are defined. The provider should be able to answer questions and clarify any confusion or concerns while the client should be able to articulate what he/she needs. Client communication is among the top priorities of Bionics Consortium who provide technical information during project updates as well as prompt responses.
Industry-specific knowledge: Assess the number of years they worked on various types of industries that require special quality standards; regulatory compliance etc. Bionics Consortium has been in operation for long thus producing braze assemblies for different industries, thus customizing them to suit your specific needs.

The Procedure

This process combines metals via a brazing filler. It takes two elements which have been prepared and books them in a drawn out vacuum furnace to the temperature of brazing for about (800-1150°C), holding them there for 10 minutes and then cooling down to solidus. This makes it possible to join ceramics and steel. The correct vacuum level must be continuously maintained throughout this process, which can also be done in an argon atmosphere.

A typical vacuum brazing treatment is as follows:

Cleaning the parts to be brazed
Braze (foil, thread, paste, powder, galvanic layer) and assembly of products
Furnace process (steered by microprocessor)
Unpacking and visual inspection
Testing / final check

Fields of Application

Characteristics associated with vacuum-brazed Furnaces are:

It gives a solid and reproducible bond that is equivalent to or better than the base material.
Create corrosion-resistant joints using precious brazing alloys.
It can withstand high temperatures (<800 °C).
Maintains a clean, hygienic joint without gaps.
Gives vacuum-tight/leak-proof seals.
Facilitates joining of dissimilar materials.
Supports one-step brazing and hardening processes.
Supports virtually all hardening operations post-brazing.
Enables a high degree of design freedom and complex product manufacturing.
Provides dimensional stability with low distortion levels.

Industrial Application

Industries we serve include: tool manufacturing, aerospace, automotive, medical, semiconductor, etc.

Advantages of Vacuum Brazing Furnace:

Fluxless braze joints with high-quality, oxide-free surfaces.
Making several joints at a time
Joining unlike materials, e.g., metal to ceramics
Brazed components have smaller internal stress as the heating and cooling process is well controlled.
It can be used for high-precision assemblies without causing distortions and displacements because of uniform temperature distribution during brazing.
step brazing using multiple braze alloys
repetitive processing

This is a Molybdenum chamber vacuum brazing furnace with a temperature of up to 1500°C.

Bionics Consortium high-temperature vacuum brazing furnace can reach 1500°C, which makes it possible to perform brazing of stainless steel, CBN, and diamond tools under vacuum. This capability also allows for sintering and heat treatment of other materials at higher temperatures because the device structurally features high vacuum and temperature possibilities.

Brazing of stainless steel
There are CBN tool brazings to be carried out.
PCD tool braze
Diamond tools braze
Copper/silver/nickel/aluminium base alloy braze

Use of Brazing Ovens

A vacuity brazing oven is employed as a finalizing technique for simple and difficult parts. Brazing ovens are more suitable than other joining techniques for multiple metal pieces because of their comparative advantage.

Furnace brazing finds application in different materials and metals. Controlled atmosphere brazing ovens are normally used to join stainless steel components for accurate connections. Nickel, copper, and silver serve as alternative metals commonly applied to braze filler materials.