Induction Heating System Topology Review

Induction Heating System Topology Review

[caption id="attachment_7044" align="alignnone" width="1024"] Induction Heating System Topology Review[/caption] All induction heating systhems are developed using electromagnetic induction which was first discovered by Michael Faraday in 1831. Electromagnetic induction refers to the phenomenon by which electric current is generated in a closed circuit by the fluctuation of current in another circuit placed next to it. The basic principle of induction heating, which is an applied form of Faraday’s discovery, is the fact that AC current flowing through a circuit affects the magnetic movement of a secondary circuit located near it. The fluctuation of current inside the primary circuit provided the answer as to how the mysterious current is generated in the neighboring secondary circuit. Faraday’s discovery led to the development of electric motors, generators, transformers, and wireless communications devices. Its application, however, has not been flawless. Heat loss, which occurs during the induction heating process, was a major headache undermining the overall functionality of a system. Researchers sought to minimize heat loss by laminating the magnetic frames placed inside the motor or transformer. Faraday’s Law was followed by a series of more advanced discoveries such as Lentz’s Law. This law explains the fact that inductive current flows inverse to the direction of changes in induction magnetic movement. Induction Heating System Topology Review

Induction Brazing Carbide to Steel

Objective High frequency induction brazing carbide to steel. Recommended Equipment The recommended equipment for this application is the DW-HF-45KW induction brazing machine with the remote heating station.

Materials:

• Large magnetic steel drill head with carbides. Head is approx. 8” OD x 4” (203.2mm OD x 101.6mm) thick, shaft is 11” (279.4mm) long x 2”(50.8mm) to 5” (127mm) OD.
• Carbides 1.125” (28.5mm) long x 0.75”(19.05mm) OD with dome shaped top attached to the head, recessed approx. 0.8” (20.3mm) into the head.

Power: Up to 37kW Temperature: 1500°F  + (815°C+) Time: Alloy flows at the outer most carbides in 50 seconds.  The center and inner carbides start to show alloy dripping at 1 minute and 40 seconds.

Results and Conclusions: Tests results show that carbide removal is possible.  Initially, the part needs to be heated and held at temperature to allow the induction brazing alloy to drip out.  It is important to fixture the part with carbides facing down.  An external shock is needed afterwards to shift the carbides out enough to allow them to be grabbed with a set of pliers. Caution: when pulling out the carbides, hot molten induction brazing alloy can flow out of the holes for the carbides when they are pulled out.

induction heating system technology PDF

Induction Heating Technology Review

1. Introduction All IH (induction heating) applied systems are developed using electromagnetic induction which was first discovered by Michael Faraday in 1831. Electromagnetic induction heating refers to the phenom- enon by which electric current is generated in a closed circuit by the fluctuation of current in another circuit placed next to it. The basic principle of induction heating, which is an applied form of Faraday’s discovery, is the fact that AC current flowing through a circuit affects the magnetic movement of a secondary circuit located near it. The fluctuation of current inside the primary circuit provided the answer as to how the mysterious current is generated in the neighboring secondary circuit. Faraday’s discovery led to the development of electric motors, generators, transformers, and wireless communications devices. Its application, however, has not been flawless. Heat loss, which occurs during the induction heating process, was a major headache undermining the overall functionality of a system. Researchers sought to minimize heat loss by laminating the magnetic frames placed inside the motor or transformer. Faraday’s Law was followed by a series of more advanced discoveries such as Lentz’s Law. This law explains the fact that inductive current flows inverse to the direction of changes in induction magnetic movement. Heat loss, occurring in the process of electromagnetic induction, could be turned into productive heat energy in an electric induction heating system by applying this law. Many industries have benefited from this new breakthrough by implementing induction heating for furnacing, induction quenching, and weld- ing. In these applications, induction heating has made it easier to set the heating parameters with- out the need of an additional external power source. This substantially reduces heat loss while maintaining a more convenient working environment. Absence of any physical contact to heating devices precludes unpleasant electrical accidents. High energy density is achieved by generating sufficient heat energy within a relatively short period of time...... Induction_Heating_System_Technology.pdf [wpforms id="3947"]  

Induction Preheating Hot Rod Heading

Induction Preheating Hot Rod Heading With IGBT Heating Units Objective Heat a waspaloy rod to 1500ºF (815.5ºC) for hot heading application Material Waspaloy rod 0.5” (12.7mm)OD, 1.5” (38.1mm) length, ceramic liner Temperature 1500 ºF (815.5ºC) Frequency 75 kHz Equipment • DW-HF- 20 kW induction heating system, equipped with a remote workhead containing two 1.32μF capacitors for a total of .66μF • An induction heating coil designed and developed specifically for this application. Process A seven turn helical coil is used to heat the rod. The rod is placed inside the coil and power is applied for two seconds providing enough heat to penetrate the inner core. An optical pyrometer is used for close loop temperature control and a ceramic liner is used so the rod does not touch the coil. Results/Benefits Induction heating provides: • Low pressure and minimal residual stress • Better grain flow and microstructure • Even distribution of heating • Improved production rates with minimal defects

Automatic Induction Forging Video

Automatic Induction Forging Video of Induction Forging Furnace with Full-automatic Feeder System

Induction Hardening of Crankshafts Machine: Improving Quality and Performance

Induction Hardening of Crankshafts Machine: Improving Quality and Performance

The Induction Hardening of Crankshafts Machine is a specialized piece of equipment used in the manufacturing process of crankshafts. It uses an induction coil to heat the surface of the crankshaft and then rapidly cools it to create a hardened layer. The machine is designed to accommodate a range of crankshaft sizes and geometries, and may include features such as automated loading and unloading, cooling systems, and process monitoring and control. The induction hardening process provides improved wear resistance and fatigue strength, which is essential for the demanding operating conditions of an engine. Crankshaft machines are a critical component of internal combustion engines, responsible for translating the reciprocating motion of the pistons into rotary motion that drives the vehicle. As such, they are subjected to high stresses and loads, which can cause wear, fatigue, and ultimately failure. To improve their quality and performance, many crankshaft machine manufacturers turn to induction hardening. Induction hardening is a surface hardening process that involves heating the surface of the crankshaft machine using an induction coil, which generates an alternating magnetic field. The heat generated by the field causes the surface of the crankshaft machine to reach a high temperature, typically above the austenitic temperature range. Once the surface has been heated to the desired temperature, it is rapidly cooled by a water spray or other quenching method. This rapid cooling causes the surface of the crankshaft machine to transform into a hardened, martensitic structure. The hardened surface layer, which is typically only a few millimeters thick, provides improved wear resistance and fatigue strength, allowing the crankshaft machine to withstand the high stresses and loads encountered during engine operation. This can result in longer service life, reduced maintenance costs, and improved performance. Induction hardening can be used on a variety of crankshaft machine materials, including low- and high-carbon steels and alloy steels. It is particularly useful for high-performance and heavy-duty crankshaft machines, which operate under extreme conditions, with high temperatures, pressures, and loads, making them especially prone to wear and fatigue. Induction hardening can help to improve the quality and performance of these machines, allowing them to operate more efficiently and reliably. Induction hardening of crankshafts is a process that involves the use of high frequency electricity to heat up specific areas of the crankshaft, followed by rapid cooling. This process creates a hardened surface layer that is more durable and resistant to wear and tear. Induction hardening of crankshafts machines are designed specifically for this process, using advanced technology to heat the crankshaft precisely and uniformly. This not only improves the durability and performance of the crankshaft, but also reduces the need for maintenance and repairs over time. If you're looking to improve the longevity and efficiency of your crankshafts, induction hardening may be the solution you need. In addition to its practical benefits, induction hardening is also an environmentally friendly process. Unlike other surface hardening methods, such as carburizing and nitriding, it does not involve the use of toxic chemicals or generate hazardous waste products. In conclusion, induction hardening is a proven surface hardening process that can significantly improve the quality and performance of crankshaft machines. By providing improved wear resistance and fatigue strength, it can help to extend the service life of these critical components, reduce maintenance costs, and improve overall machine performance. With its many practical benefits and environmentally friendly nature, it is an ideal choice for crankshaft machine manufacturers looking to improve the reliability and efficiency of their products.

Induction Hardening of Crankshafts Machine: Improving Quality and Performance

Induction Hardening of Crankshafts Machine: Improving Quality and Performance

The Induction Hardening of Crankshafts Machine is a specialized piece of equipment used in the manufacturing process of crankshafts. It uses an induction coil to heat the surface of the crankshaft and then rapidly cools it to create a hardened layer. The machine is designed to accommodate a range of crankshaft sizes and geometries, and may include features such as automated loading and unloading, cooling systems, and process monitoring and control. The induction hardening process provides improved wear resistance and fatigue strength, which is essential for the demanding operating conditions of an engine. Crankshaft machines are a critical component of internal combustion engines, responsible for translating the reciprocating motion of the pistons into rotary motion that drives the vehicle. As such, they are subjected to high stresses and loads, which can cause wear, fatigue, and ultimately failure. To improve their quality and performance, many crankshaft machine manufacturers turn to induction hardening. Induction hardening is a surface hardening process that involves heating the surface of the crankshaft machine using an induction coil, which generates an alternating magnetic field. The heat generated by the field causes the surface of the crankshaft machine to reach a high temperature, typically above the austenitic temperature range. Once the surface has been heated to the desired temperature, it is rapidly cooled by a water spray or other quenching method. This rapid cooling causes the surface of the crankshaft machine to transform into a hardened, martensitic structure. The hardened surface layer, which is typically only a few millimeters thick, provides improved wear resistance and fatigue strength, allowing the crankshaft machine to withstand the high stresses and loads encountered during engine operation. This can result in longer service life, reduced maintenance costs, and improved performance. Induction hardening can be used on a variety of crankshaft machine materials, including low- and high-carbon steels and alloy steels. It is particularly useful for high-performance and heavy-duty crankshaft machines, which operate under extreme conditions, with high temperatures, pressures, and loads, making them especially prone to wear and fatigue. Induction hardening can help to improve the quality and performance of these machines, allowing them to operate more efficiently and reliably. Induction hardening of crankshafts is a process that involves the use of high frequency electricity to heat up specific areas of the crankshaft, followed by rapid cooling. This process creates a hardened surface layer that is more durable and resistant to wear and tear. Induction hardening of crankshafts machines are designed specifically for this process, using advanced technology to heat the crankshaft precisely and uniformly. This not only improves the durability and performance of the crankshaft, but also reduces the need for maintenance and repairs over time. If you're looking to improve the longevity and efficiency of your crankshafts, induction hardening may be the solution you need. In addition to its practical benefits, induction hardening is also an environmentally friendly process. Unlike other surface hardening methods, such as carburizing and nitriding, it does not involve the use of toxic chemicals or generate hazardous waste products. In conclusion, induction hardening is a proven surface hardening process that can significantly improve the quality and performance of crankshaft machines. By providing improved wear resistance and fatigue strength, it can help to extend the service life of these critical components, reduce maintenance costs, and improve overall machine performance. With its many practical benefits and environmentally friendly nature, it is an ideal choice for crankshaft machine manufacturers looking to improve the reliability and efficiency of their products. https://dw-inductionheater.com/product/induction-hardening-of-crankshafts-machine-improving-quality-and-performance?feed_id=200935&_unique_id=644e70417be41

induction brazing stainless steel to steel

High frequency magnetic induction brazing stainless steel to steel process

HLQ team was provided with 2 different parts to be brazed in our test laboratory. Objective: Induction Brazing of a 0.15’’/ 3.81mm stainless steel pin to a steel base. Equipment:  DW-UHF-6KW-III handheld induction brazing system  Industry: Appliances & HVAC Materials: Steel hexagon (base 1’’/ 25.4 mm diameter; 0.1’’/ 2.54 mm wall thickness) A stainless steel pin (0.15’’/ 3.81 mm) Other Materials:  All-purpose black brazing flux Power: 1.43 kW Temperature: 1400 °F/ 760°C Time: 8 seconds Process: The two workpieces were carefully positioned together. All-purpose induction brazing black flux was added because it is ideal for high-temperature applications where rapid, localized heating is needed. The process of induction brazing was performed successfully within 8 seconds by using the  DW-UHF-6KW-III handheld induction brazing system, producing the induction heating power of 1.43 kW at 1400 °F/ 760°C.

Induction Wire and Cable Heating

Induction wire and cable heater is also used for the induction preheating, post heating or annealing of metallic wire along with the bonding/vulcanization of insulating or shielding within various cable products. Preheating applications can include heating wire prior to drawing it down or extruding. Post heating would typically include processes such a bonding, vulcanizing, curing or drying paint, adhesives or insulating materials. In addition to providing accurate heat and typically faster line speeds, the output power of the induction heating power supply can be controlled via the line speed of the system in most cases.

What is induction wire and cable heating?

HLQ Induction offers solutions for many applications from structural ferrous and non-ferrous wires, copper and aluminium cable and conductors to fibre optic production. The applications are very wide ranging including, but not limited to, forming, forging, heat treatment, galvanizing, coating, drawing etc. at temperatures from 10’s of degrees to in excess of 1,500 degrees.

What are the advantages of induction wire and cable heating?

The systems can be employed as your total heating solution or as a booster to improve the productivity of an existing furnace by acting as a preheater. Our induction heating solutions are renowned for their compactness, productivity and efficiency. Whilst we supply a range of solutions, most are optimised to meet your specific requirements.

Where is induction wire and cable heating used?

Typical applications include: -Drying post cleaning or removing water or solvent from coatings -Curing of liquid or powder based coatings. Providing a superior bond strength and surface finish -Diffusion of metallic coating -Pre heating for extrusion of polymer and metallic coatings -Heat treatment including: stress relieving, tempering, annealing, bright annealing, hardening, patenting etc. -Pre-heating for hot-forming or forging, especially important for specification alloys. The unrivalled accuracy, control and efficiency of induction heating makes it ideal for many key tasks in the manufacture and processing of wire and cable products. Objective Heat several different wire diameters to 204°C (400°F) in 0.8 seconds with the same induction coil. Equipment: DW-UHF-6KW-III induction heater Process Steps: 1. Clean and apply 204°C (400°F) Tempilaq over the length of the wire. 2. Apply induction heat for 0.8 seconds. Results and Conclusions: All wires exceeded 204°C (400°F) over full length of coil. Further development testing will be required to optimize the equipment for the application for the fastest rates available. Tuning and optimization of the equipment would need to be done with a continuous wire feed in the unit. Based on the results, a 6kW induction heating power supply can be used, and further development testing would guarantee the desired rates. A 10kW induction heating power supply will recommended. The additional power will make the tuning and development testing easier for the end user and leave additional power for production rates to be easily increased in the future.

Induction crankshaft hardening surface

Induction Crankshaft Hardening: The Ultimate Guide to Durable Engines

Crankshafts are the heart of internal combustion engines. They transfer motion from pistons to the drive shaft, powering your vehicle. As engines are subject to extreme stresses, ensuring the durability of the crankshaft is vital to the longevity of the engine. Induction crankshaft hardening is a heat treatment process that can produce superior durability and strength in crankshafts, making them a popular choice among engine manufacturers. In this guide, we'll explain everything you need to know about induction crankshaft hardening and its benefits.

What is Induction Crankshaft Hardening?

Induction crankshaft hardening is a process used in the manufacturing of engines that can significantly improve engine performance. The process involves heating the crankshaft to a high temperature and then quenching it in a controlled manner. The result is a crankshaft that has a hard outer layer, which improves wear resistance and reduces the risk of damage to the engine. This process is typically used in racing engines, where reliability and performance are essential. Induction crankshaft hardening is also becoming more common in high-performance street engines, due to the significant benefits it can provide. The process is performed using a specialized induction heating system, which applies heat to the crankshaft in a controlled and precise manner. With the increased durability and performance benefits that come with induction crankshaft hardening, it's no wonder that it is becoming a popular choice for engine manufacturers and high-performance engine builders alike.

Benefits of Induction Crankshaft Hardening

Induction crankshaft hardening is a process that can bring numerous benefits to engine performance. The primary benefit of induction crankshaft hardening is that it greatly increases the durability and strength of the crankshaft. Induction crankshaft hardening offers several benefits, including: 1. Increased durability and wear resistance: Induction hardening produces a hardened shell on the surface layer of the crankshaft. The hardened shell can resist wear and scratches, providing long-lasting durability. 2. Improved fatigue strength: The hardened layer makes the crankshaft more resistant to fatigue, which can help prevent engine failures. 3. Better performance: Induction hardening improves the surface quality of the crankshaft, reducing friction and increasing engine performance. 4. Cost-effective: Induction hardening is a cost-effective heat treatment process compared to other methods, saving manufacturers money while producing high-quality crankshafts. This is important because the crankshaft is the backbone of the engine, and it is responsible for transferring the power from the engine to the drive train. A stronger crankshaft means that the engine can handle more power and torque, which can result in better performance. Instead of using more expensive materials to create stronger crankshafts, induction hardening can be used to strengthen existing crankshafts. This can reduce the cost of manufacturing engines, making them more accessible to consumers. Overall, the benefits of induction crankshaft hardening are clear. By increasing durability, wear resistance, efficiency, and cost-effectiveness, this process can greatly enhance engine performance and longevity.

How Induction Crankshaft Hardening Can Boost Engine Performance

Induction crankshaft hardening is a process used in the automotive industry to increase the performance of engines. This process involves heating the crankshaft to a high temperature and then rapidly cooling it to create a hardened surface. Induction hardening is a popular method because it is a cost-effective way of hardening crankshafts without the need for additional materials or treatments. When an engine is running, the crankshaft is subjected to a lot of stress and pressure. As a result, the crankshaft can wear down over time, leading to reduced engine performance. By hardening the crankshaft, the engine's performance can be improved. A hardened crankshaft can withstand more stress and pressure, allowing it to perform better. Induction crankshaft hardening can also improve the engine's fuel efficiency. A hardened crankshaft reduces the amount of friction in the engine, which means that the engine can run more efficiently. This is because the engine doesn't have to work as hard to produce the same amount of power. Another benefit of induction crankshaft hardening is that it can increase the lifespan of the engine. As the crankshaft is one of the most critical components in an engine, hardening it can help to prevent premature failure. This means that the engine can last longer, and the vehicle owner can save money on repairs and replacements. Overall, induction crankshaft hardening is an excellent way to boost engine performance, improve fuel efficiency, and increase the lifespan of the engine. If you are looking for a way to get the most out of your vehicle, consider having your engine's crankshaft hardened through the process of induction hardening.

Why Choose Induction Crankshaft Hardening?

Induction crankshaft hardening is an ideal method for ensuring the durability of crankshafts, especially in high-performance engines. Induction hardening can produce high-quality crankshafts with precise depth and consistent hardness throughout the surface layer. Moreover, the heat input can be controlled easily, allowing manufacturers to adjust the hardening process according to the specific requirements of the crankshaft. Induction crankshaft hardening is also eco-friendly. The process requires less energy, reducing the carbon footprint and improving sustainability.

Conclusion.

induction crankshaft hardening is a process that can significantly improve the performance of your engine. It allows for stronger, more durable crankshafts that can handle higher levels of stress and pressure. With the ability to withstand higher RPMs and temperatures, your engine can deliver more power and better performance. Additionally, the induction hardening process is environmentally friendly and cost-effective, making it an ideal choice for those looking to upgrade their engines without breaking the bank. So if you're looking to take your engine's performance to the next level, consider incorporating induction crankshaft hardening into your engine rebuilding process. It can be a game-changer for your vehicle's performance and longevity.

induction preheating copper rod

high frequency induction preheating copper rod and connector for an epoxy curing application

induction preheating copper rod and connector for an epoxy curing application Objective: To preheat a portion of the copper rod and a rectangular connector to temperature prior to epoxy curing during a manufacturing process for electrical turnbuckles Material : Customer supplied plated copper rod (12” x 2” x 1”/305mm x 51mm x 102 mm) and connector Temperature :302 ºF (150 ºC) Frequency :25 kHz Induction Heating Equipment: -DW-HF-60kW 15-45 kHz induction heating system equipped with a remote workhead containing four 21 μF capacitors - A single position seven-turn helical induction heating coil designed and developed specifically for this application Induction Heating Process The copper rod and connector were placed inside the induction heating coil and the power was turned on. The part heated to temperature within 55 seconds. After being heated to temperature, the part was moved and an epoxy curing/molding process took place. The client was using a large oven to preheat these rods, which was cost inefficient. Induction offers a faster and more costefficient heating method. Results/Benefits - Speed: Induction heated the part to temperature quickly - Efficiency: Induction is a far more efficient method of heating these parts to temperature when compared to their large oven - Precision: Induction made it possible to heat only the parts of the rod that required heating

Induction crankshaft hardening surface

Induction Crankshaft Hardening: The Ultimate Guide to Durable Engines

Crankshafts are the heart of internal combustion engines. They transfer motion from pistons to the drive shaft, powering your vehicle. As engines are subject to extreme stresses, ensuring the durability of the crankshaft is vital to the longevity of the engine. Induction crankshaft hardening is a heat treatment process that can produce superior durability and strength in crankshafts, making them a popular choice among engine manufacturers. In this guide, we'll explain everything you need to know about induction crankshaft hardening and its benefits.

What is Induction Crankshaft Hardening?

Induction crankshaft hardening is a process used in the manufacturing of engines that can significantly improve engine performance. The process involves heating the crankshaft to a high temperature and then quenching it in a controlled manner. The result is a crankshaft that has a hard outer layer, which improves wear resistance and reduces the risk of damage to the engine. This process is typically used in racing engines, where reliability and performance are essential. Induction crankshaft hardening is also becoming more common in high-performance street engines, due to the significant benefits it can provide. The process is performed using a specialized induction heating system, which applies heat to the crankshaft in a controlled and precise manner. With the increased durability and performance benefits that come with induction crankshaft hardening, it's no wonder that it is becoming a popular choice for engine manufacturers and high-performance engine builders alike.

Benefits of Induction Crankshaft Hardening

Induction crankshaft hardening is a process that can bring numerous benefits to engine performance. The primary benefit of induction crankshaft hardening is that it greatly increases the durability and strength of the crankshaft. Induction crankshaft hardening offers several benefits, including: 1. Increased durability and wear resistance: Induction hardening produces a hardened shell on the surface layer of the crankshaft. The hardened shell can resist wear and scratches, providing long-lasting durability. 2. Improved fatigue strength: The hardened layer makes the crankshaft more resistant to fatigue, which can help prevent engine failures. 3. Better performance: Induction hardening improves the surface quality of the crankshaft, reducing friction and increasing engine performance. 4. Cost-effective: Induction hardening is a cost-effective heat treatment process compared to other methods, saving manufacturers money while producing high-quality crankshafts. This is important because the crankshaft is the backbone of the engine, and it is responsible for transferring the power from the engine to the drive train. A stronger crankshaft means that the engine can handle more power and torque, which can result in better performance. Instead of using more expensive materials to create stronger crankshafts, induction hardening can be used to strengthen existing crankshafts. This can reduce the cost of manufacturing engines, making them more accessible to consumers. Overall, the benefits of induction crankshaft hardening are clear. By increasing durability, wear resistance, efficiency, and cost-effectiveness, this process can greatly enhance engine performance and longevity.

How Induction Crankshaft Hardening Can Boost Engine Performance

Induction crankshaft hardening is a process used in the automotive industry to increase the performance of engines. This process involves heating the crankshaft to a high temperature and then rapidly cooling it to create a hardened surface. Induction hardening is a popular method because it is a cost-effective way of hardening crankshafts without the need for additional materials or treatments. When an engine is running, the crankshaft is subjected to a lot of stress and pressure. As a result, the crankshaft can wear down over time, leading to reduced engine performance. By hardening the crankshaft, the engine's performance can be improved. A hardened crankshaft can withstand more stress and pressure, allowing it to perform better. Induction crankshaft hardening can also improve the engine's fuel efficiency. A hardened crankshaft reduces the amount of friction in the engine, which means that the engine can run more efficiently. This is because the engine doesn't have to work as hard to produce the same amount of power. Another benefit of induction crankshaft hardening is that it can increase the lifespan of the engine. As the crankshaft is one of the most critical components in an engine, hardening it can help to prevent premature failure. This means that the engine can last longer, and the vehicle owner can save money on repairs and replacements. Overall, induction crankshaft hardening is an excellent way to boost engine performance, improve fuel efficiency, and increase the lifespan of the engine. If you are looking for a way to get the most out of your vehicle, consider having your engine's crankshaft hardened through the process of induction hardening.

Why Choose Induction Crankshaft Hardening?

Induction crankshaft hardening is an ideal method for ensuring the durability of crankshafts, especially in high-performance engines. Induction hardening can produce high-quality crankshafts with precise depth and consistent hardness throughout the surface layer. Moreover, the heat input can be controlled easily, allowing manufacturers to adjust the hardening process according to the specific requirements of the crankshaft. Induction crankshaft hardening is also eco-friendly. The process requires less energy, reducing the carbon footprint and improving sustainability.

Conclusion.

induction crankshaft hardening is a process that can significantly improve the performance of your engine. It allows for stronger, more durable crankshafts that can handle higher levels of stress and pressure. With the ability to withstand higher RPMs and temperatures, your engine can deliver more power and better performance. Additionally, the induction hardening process is environmentally friendly and cost-effective, making it an ideal choice for those looking to upgrade their engines without breaking the bank. So if you're looking to take your engine's performance to the next level, consider incorporating induction crankshaft hardening into your engine rebuilding process. It can be a game-changer for your vehicle's performance and longevity. https://dw-inductionheater.com/product/induction-crankshaft-hardening-surface?feed_id=200762&_unique_id=644dcb4ae0db6

Aluminum Tubes Induction Brazing

In order to increase the efficiency and to reduce the thermal effect of metal heating, the induction brazing technology is proposed. Advantage of this technology consists mainly in exact location of heating supplied to the brazed joints. Based on the results of numerical simulation it was then possible to design the parameters necessary to achieve brazing temperatures in the desired time. The aim was to minimize this time to avoid an undesired thermal effect on the metals during metallurgical joining.The results of numerical simulation revealed that increasing the current frequency resulted in concentration of maximum temperatures in surface areas of joined metals. With increasing current, the reduction of time required for reaching the brazing temperature was observed.

The advantages of induction brazing of aluminum vs. torch or flame brazing

The low melting temperature of aluminum base metals coupled with the narrow temperature process window of the braze alloys used is a challenge when torch brazing.  The lack of color change while heating aluminum does not provide braze operators any visual indication that the aluminum has reached the proper brazing temperature.  Braze operators introduce a number of variables when torch brazing.  Among these include torch settings and flame type; distance from torch to parts being brazed; location of flame relative to parts being joined; and more. Reasons to consider using induction heating when brazing aluminum include:

• Quick, rapid heating
• Controlled, precise heat control
• Selective (localized) heat
• Production line adaptability and integration
• Improved fixture life and simplicity
• Repeatable, reliable brazed joints
• Improved safety

Successful induction brazing of aluminum components is highly dependent on designing induction heating coils to focus the electromagnetic heat energy into the areas to be brazed and to heat them uniformly so that the braze alloy melts and flows properly.  Improperly designed induction coils can result in some areas being overheated and other areas not receiving enough heat energy resulting in an incomplete braze joint. For a typical brazed aluminum tube joint, an operator installs an aluminum braze ring, often containing flux, on the aluminum tube and inserts this into another expanded tube or a block fitting.  The parts are then placed into an induction coil and heated.  In a normal process, the braze filler metals melt and flow into the joint interface due to capillary action.

Why induction braze vs. torch braze aluminum components?

First, a little background on common aluminum alloys prevalent today and the common aluminum braze and solders used for joining.  Brazing aluminum components is much more challenging than brazing copper components.  Copper melts at 1980°F (1083°C) and it changes color as it is heated.  Aluminum alloys often used in HVAC systems start to melt at approximately 1190°F (643°C) and do not provide any visual cues, such as color changes, as it heats. Very precise temperature control is required as the difference in the melting and brazing temperatures for aluminum, dependent upon the aluminum base metal, braze filler metal, and mass of the components to be brazed.  For example, The temperature difference between solidus temperature of two common aluminum alloys, 3003 series aluminum, and 6061 series aluminum, and the liquid’s temperature of frequently used BAlSi-4 braze alloy is 20°F – a very narrow temperature process window, thus necessitating precise control. The selection of base alloys is extremely important with aluminum systems that are being brazed. The best practice is to braze at a temperature that is below the solidus temperature of the alloys the make up the components being brazed together.

AWS A5.8 Classification	Nominal Chemical Composition	Solidus °F (°C)	Liquidus °F(°C)	Brazing Temperature
BAISi-3	86% Al 10%Si 4%Cu	970 (521)	1085 (855)	1085~1120 °F
BAISI-4	88% aL 12%Si	1070 (577)	1080 (582)	1080~1120 °F
	78 Zn 22%Al	826 (441)	905(471)	905~950 °F
	98% Zn 2%Al	715(379)	725(385)	725~765 °F

It should be noted that galvanic corrosion can occur between zinc-rich areas and aluminum.  As noted in the galvanic chart in Figure 1, zinc is less noble and tends to be anodic compared to aluminum.  The lower the potential difference, the lower the rate of corrosion.  The potential difference between zinc and aluminum is minimal compared to the potential between aluminum and copper. Another phenomenon when aluminum is brazed with a zinc alloy is pitting. Local cell or pitting corrosion can occur on any metal. Aluminum is normally protected by a hard, thin film that forms at the surface when they are exposed to oxygen (aluminum oxide) but when a flux removes this protective oxide layer, dissolution of the aluminum can occur.  The longer the filler metal remains molten, the more severe the dissolution is. Aluminum forms a tough oxide layer during brazing, so the use of flux is essential. Fluxing aluminum components can be done separately prior to brazing or an aluminum brazing alloy containing flux can be incorporated into the brazing process. Depending upon the type of flux used (corrosive vs. non-corrosive), an additional step may be required if the flux residue must be removed after brazing.  Consult with a braze and flux manufacturer to get recommendations on brazing alloy and flux based on the materials being joined and the expected brazing temperatures.   Aluminum Tubes Induction Brazing

induction curing

What is induction curing?

How does induction curing work? Simply put, line power is converted to alternating current and delivered to a work coil which creates an electromagnetic field within the coil. The piece with the epoxy on it can be metal or a semiconductor such as carbon or graphite. To cure epoxy on non-conductive substrates such as glass, an electrically conductive susceptor can be used to transfer the heat to the non-conductive material. [caption id="attachment_6981" align="alignnone" width="721"] induction curing principle-theory[/caption]

What are the benefits of induction curing?

Single component epoxy adhesives that are heat cured can use heat from various sources. The most typical is an oven but heat air guns, bake plates and induction curing are also used. Induction curing can greatly reduce the amount of time required to cure the epoxy and minimize the effects of heat on surrounding components as induction heating delivers heat precisely to the adhesive area.

Is induction curing a good option for my application?

Providing your induction heating equipment specialist and your epoxy adhesive manufacturer information on the following topics will help them to make the best recommendation. 1. Materials or substrates being bonded – Understanding what the substrates are will help determine the heating rate and power needed to cure the adhesive. For example iron heats with less power than is needed to heat aluminium. 2. Size of the components being bonded – Smaller parts require a higher frequency for efficient heating. Larger areas benefit from a lower frequency. 3. Epoxy requirements – There is a min/max threshold for curing epoxy. The minimum temperature required to effect cure and the maximum temperature allowed prior to the breakdown of the epoxy.

Induction Curing for Bonding of Quartz Chip to a Steel Cylinder

A company in the Automotive industry is looking for an induction heating system that can reach the temperature of 175° C (347°F) and hold it within the tight tolerance of +/- 3 C. Induction heating will heat a steel cylinder to cure an adhesive for bonding of a quartz chip. Induction heating is a preferred method because it provides faster, controlled and more uniform heating. Industry: Automotive Equipment: DW-UHF-10kW induction heating system is recommended for this curing application to ramp up and hold the desired temperature. Process: The goal of this induction curing application is to heat two sides of a steel cylinder which is 1.064” (2.70 cm) OD, 7.25” (18.41 cm) long with a 1” (2.54 cm) heat zone up to 175 C (347°F) and hold that temperature for 60 seconds in order to perform bonding application. The desired temperature was reached in 13 seconds. A K-type temperature controller was used to measure the temperature. [caption id="attachment_6979" align="alignnone" width="1024"] induction curing process[/caption] Induction Curing for Bonding of Quartz Chip to a Steel Cylinder