Induction Hardening Surface Process

Induction Hardening Surface Process Applicatons

What is induction hardening ?

Induction hardening is a form of heat treatment in which a metal part with sufficient carbon content is heated in the induction field and then rapidly cooled. This increases both the hardness and brittleness of the part. Induction heating allows you to have localized heating to a pre-determined temperature and enables you to precisely control the hardening process. Process repeatability is thus guaranteed. Usually, induction hardening is applied to metal parts which need to have great surface wear resistance, while at the same time retaining their mechanical properties. After the induction hardening process is achieved, the metal workpiece needs to be quenched in water, oil or air inorder to obtain specific properties of the surface layer. Induction hardening is a method of quickly and selectively hardening the surface of a metal part. A copper coil carrying a significant level of alternating current is placed near (not touching) the part. Heat is generated at, and near the surface by eddy current and hysteresis losses. Quench, usually water-based with an addition such as a polymer, is directed at the part or it is submerged. This transforms the structure to martensite, which is much harder than the prior structure. A popular, modern type of induction hardening equipment is called a scanner. The part is held between centers, rotated, and passed through a progressive coil which provides both heat and quench. The quench is directed below the coil, so any given area of the part is rapidly cooled immediately following heating. Power level, dwell time, scan (feed) rate and other process variables are precisely controlled by a computer. Case hardening process used to increase wear resistance, surface hardness and fatigue life through creation of a hardened surface layer while maintaining an unaffected core microstructure.

Induction hardening is used to increase the mechanical properties of ferrous components in a specific area. Typical applications are powertrain, suspension, engine components and stampings. Induction hardening is excellent at repairing warranty claims / field failures. The primary benefits are improvements in strength, fatigue and wear resistance in a localised area without having to redesign the component.

Processes and Industries that can benefit from induction hardening:

• Heat-treatment
• Chain hardening
• Tube & Pipe Hardening
• Shipbuilding
• Aerospace
• Railway
• Automotive
• Renewable energies

Benefits of Induction Hardening:

Favoured for components that are subjected to heavy loading. Induction imparts a high surface hardness with a deep case capable of handling extremely high loads. Fatigue strength is increased by the development of a soft core surrounded by an extremely tough outer layer. These properties are desirable for parts that experience torsional loading and surfaces that experience impact forces. Induction processing is performed one part at a time allowing for very predictable dimensional movement from part to part.

• Precise control over temperature and hardening depth
• Controlled and localized heating
• Easily integrated into production lines
• Fast and repeatable process
• Each workpiece can be hardened by precise optimized parameters
• Energy-efficient process

Steel and stainless-steel components that can be hardened with induction: Fasteners, flanges, gears, bearings, tube, inner and outer races, crankshafts, camshafts, yokes, drive shafts, output shafts, spindles, torsion bars, slewing rings, wire, valves, rock drills, etc.

Increased Wear Resistance

There is a direct correlation between hardness and wear resistance. The wear resistance of a part increases significantly with induction hardening, assuming the initial state of the material was either annealed, or treated to a softer condition.

Increased Strength & Fatigue Life due to the Soft Core & Residual Compressive Stress at the Surface

The compressive stress (usually considered a positive attribute) is a result of the hardened structure near the surface occupying slightly more volume than the core and prior structure.

Parts may be Tempered after Induction Hardening to Adjust Hardness Level, as desired

As with any process producing a martensitic structure, tempering will lower hardness while decreasing brittleness.

Deep Case with Tough Core

Typical case depth is .030” - .120” which is deeper on average than processes such as carburizing, carbonitriding, and various forms of nitriding performed at sub-critical temperatures. For certain projects such as axels, or parts which are still useful even after much material has worn away, case depth may be up to ½ inch or greater.

Selective Hardening Process with No Masking Required

Areas with post-welding or post-machining stay soft - very few other heat treat processes are able to achieve this.

Relatively Minimal Distortion

Example: a shaft 1” Ø x 40” long, which has two evenly spaced journals, each 2” long requiring support of a load and wear resistance. Induction hardening is performed on just these surfaces, a total of 4” length. With a conventional method (or if we induction hardened the entire length for that matter), there would be significantly more warpage.

Allows use of Low Cost Steels such as 1045

The most popular steel utilized for parts to be induction hardened is 1045. It is readily machinable, low cost, and due to a carbon content of 0.45% nominal, it may be induction hardened to 58 HRC +. It also has a relatively low risk of cracking during treatment. Other popular materials for this process are 1141/1144, 4140, 4340, ETD150, and various cast irons.

Limitations of Induction Hardening

Requires an Induction Coil and Tooling which relates to the Part’s Geometry

Since the part-to-coil coupling distance is critical to heating efficiency, the coil’s size and contour must be carefully selected. While most treaters have an arsenal of basic coils to heat round shapes such as shafts, pins, rollers etc., some projects may require a custom coil, sometimes costing thousands of dollars. On medium to high volume projects, the benefit of reduced treatment cost per part may easily offset coil cost. In other cases, the engineering benefits of the process may outweigh cost concerns. Otherwise, for low volume projects the coil and tooling cost usually makes the process impractical if a new coil must be built. The part must also be supported in some manner during the treatment. Running between centers is a popular method for shaft type parts, but in many other cases custom tooling must be utilized.

Greater Likelihood of Cracking Compared to most Heat Treatment Processes

This is due to the rapid heating and quenching, also the tendency to create hot spots at features/edges such as: keyways, grooves, cross holes, threads.

Distortion with Induction Hardening

Distortion levels do tend to be greater than processes such as ion or gas nitriding, due to the rapid heat/quench and resultant martensitic transformation. That being said, induction hardening may produce less distortion than conventional heat treat, particularly when it’s only applied to a selected area.

Material Limitations with Induction Hardening

Since the induction hardening process does not normally involve diffusion of carbon or other elements, the material must contain enough carbon along with other elements to provide hardenability supporting martensitic transformation to the level of hardness desired. This typically means carbon is in the 0.40%+ range, producing hardness of 56 – 65 HRC. Lower carbon materials such as 8620 may be used with a resultant reduction in achievable hardness (40-45 HRC in this case). Steels such as 1008, 1010, 12L14, 1117 are typically not used due to the limited increase in hardness achievable.

Induction Hardening Surface Process details

Induction hardening is a process used for the surface hardening of steel and other alloy components. The parts to be heat treated are placed inside a copper coil and then heated above their transformation temperature by applying an alternating current to the coil. The alternating current in the coil induces an alternating magnetic field within the work piece which causes the outer surface of the part to heat to a temperature above the transformation range. The components are heated by means of an alternating magnetic field to a temperature within or above the transformation range followed by immediate quenching. It is an electromagnetic process using a copper inductor coil, which is fed a current at a specific frequency and power level.   https://dw-inductionheater.com/induction-hardening-surface-process.html?feed_id=216961&_unique_id=649f2767a826c

What is induction tempering?

What is induction tempering? Induction tempering is a heating process that optimizes mechanical properties such as toughness and ductility in workpieces that have already been hardened. What are the benefits? The main advantage of induction over furnace tempering is speed. Induction can temper workpieces in minutes, sometimes even seconds. Furnaces typically take hours. And as induction tempering is perfect for inline integration, it minimizes the number of components in process. Induction tempering facilitates quality control of individual workpieces. Integrated induction temper stations also save valuable floor space. Where is it used? Induction tempering is widely employed in the automotive industry to temper surface-hardened components such as shafts, bars and joints. The process is also used in the tube and pipe industry to temper throughhardened workpieces. Induction tempering is sometimes performed in the hardening station, sometimes in one or several separate temper stations. What equipment is available? Complete HardLine systems are ideal for many tempering applications. The chief benefit of such systems is that hardening and tempering are performed by one machine. This delivers significant time and cost savings in a small footprint compared to alternative technologies. With furnaces, for example, one furnace often first hardens the workpieces, with a separate furnace then being used for tempering. Solid state DAWEI Induction Heating Systems are also used for tempering applications.

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction brazing copper lap joints is a highly effective method for joining copper components with precision and strength. The process involves using an induction heating system to generate heat directly within the copper material, allowing for a localized and controlled heating of the joint area. The brazing filler metal, typically a copper-based alloy, is then introduced to the heated joint, melting and flowing into the gap to create a strong, durable bond. Induction brazing offers several benefits including rapid heating, minimal distortion, and the ability to join dissimilar metals. If you are looking for a reliable and efficient method to braze copper lap joints, induction brazing is the way to go. 1. The Advantages of Induction Brazing Copper Lap Joints 1.1. Precise Heat Control: Induction brazing allows for precise and localized heating, minimizing the risk of thermal damage to the surrounding areas. This is especially important when working with sensitive copper components or assemblies with complex geometries. 1.2. Increased Efficiency: Induction heating is fast and efficient, as it directly heats the workpiece without the need for preheating the entire assembly. This results in reduced energy consumption, shorter cycle times, and increased productivity. 1.3. Stronger Joints: Induction brazing produces high-quality joints with excellent bond strength. The controlled heating process ensures uniform heating and proper filler metal flow, resulting in robust and reliable connections. 1.4. Clean and Environmentally Friendly: Induction brazing eliminates the need for open flames or torches, minimizing the risk of contamination and creating a safer working environment. Additionally, it reduces the generation of harmful fumes and pollutants, making it an eco-friendly choice. 2. The Induction Brazing Process for Copper Lap Joints 2.1. Preparation: Thoroughly clean the copper surfaces to remove any contaminants, such as dirt, grease, or oxide layers. This ensures optimal bonding and prevents defects in the joint. 2.2. Filler Metal Selection: Choose a brazing filler metal that is compatible with copper and suitable for your specific application. Silver-based alloys, such as silver-copper-phosphorus, or copper-phosphorus alloys are commonly used for copper brazing. 2.3. Joint Assembly: Position the copper parts in a lap joint configuration, ensuring a close fit. Fixtures or clamps can be used to secure the parts during the brazing process. 2.4. Flux Application: Apply a suitable flux to the joint area. The flux removes oxide layers, promotes wetting of the filler metal, and prevents oxidation during heating. Select a flux specifically formulated for brazing copper. 2.5. Induction Heating: Position the copper assembly within the induction coil, ensuring the joint area is within the heating zone. Adjust the induction heating system's power, frequency, and parameters based on manufacturer guidelines and the size/thickness of the copper parts. 2.6. Filler Metal Introduction: Once the joint area reaches the brazing temperature, introduce the filler metal. It can be in the form of a pre-placed filler wire or applied directly as a brazing paste or powder. The heat from the induction process melts the filler metal, allowing it to flow into the joint. 2.7. Cooling and Cleaning: After the filler metal has completely filled the joint, switch off the power and allow the joint to cool naturally. Once cooled, remove any residual flux or oxide from the brazed joint using appropriate cleaning methods. 3. Applications of Induction Brazing Copper Lap Joints 3.1. Electrical and Electronics Industry: Induction brazing is widely used in manufacturing electrical connectors, motor windings, transformers, and various electronic components that require reliable electrical conductivity and mechanical strength. 3.2. HVAC and Refrigeration: Copper tube connections in air conditioning, refrigeration, and heat exchanger systems often employ induction brazing for its efficiency, accuracy, and consistent quality. 3.3. Automotive and Aerospace: Induction brazing is utilized in the production of automotive heat exchangers, fuel systems, and aerospace components, ensuring reliable performance under demanding conditions. 3.4. Plumbing and Pipe Fittings: Copper plumbing fittings, valves, and pipe joints can be efficiently and effectively brazed using induction, providing leak-free connections and extended service life. Conclusion Induction brazing copper lap joints is a highly efficient and effective method of joining two copper pieces together. The process involves using an induction heating system to heat the joint area, melting a filler metal, and creating a strong bond between the copper pieces. This technique offers several advantages, including precise and localized heating, minimal distortion, and faster heating cycles. Induction brazing also ensures a clean and contamination-free joint, resulting in superior quality and strength. Whether you require brazing for plumbing, electronics, or any other copper applications, our skilled technicians are ready to provide reliable and durable solutions. Trust our expertise in induction brazing copper lap joints for a seamless and robust joining process that meets your specific needs. https://dw-inductionheater.com/induction-brazing-copper-lap-joints-a-reliable-and-efficient-joining-method.html?feed_id=216886&_unique_id=649eeca9c814e

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction brazing copper lap joints is a highly effective method for joining copper components with precision and strength. The process involves using an induction heating system to generate heat directly within the copper material, allowing for a localized and controlled heating of the joint area. The brazing filler metal, typically a copper-based alloy, is then introduced to the heated joint, melting and flowing into the gap to create a strong, durable bond. Induction brazing offers several benefits including rapid heating, minimal distortion, and the ability to join dissimilar metals. If you are looking for a reliable and efficient method to braze copper lap joints, induction brazing is the way to go. 1. The Advantages of Induction Brazing Copper Lap Joints 1.1. Precise Heat Control: Induction brazing allows for precise and localized heating, minimizing the risk of thermal damage to the surrounding areas. This is especially important when working with sensitive copper components or assemblies with complex geometries. 1.2. Increased Efficiency: Induction heating is fast and efficient, as it directly heats the workpiece without the need for preheating the entire assembly. This results in reduced energy consumption, shorter cycle times, and increased productivity. 1.3. Stronger Joints: Induction brazing produces high-quality joints with excellent bond strength. The controlled heating process ensures uniform heating and proper filler metal flow, resulting in robust and reliable connections. 1.4. Clean and Environmentally Friendly: Induction brazing eliminates the need for open flames or torches, minimizing the risk of contamination and creating a safer working environment. Additionally, it reduces the generation of harmful fumes and pollutants, making it an eco-friendly choice. 2. The Induction Brazing Process for Copper Lap Joints 2.1. Preparation: Thoroughly clean the copper surfaces to remove any contaminants, such as dirt, grease, or oxide layers. This ensures optimal bonding and prevents defects in the joint. 2.2. Filler Metal Selection: Choose a brazing filler metal that is compatible with copper and suitable for your specific application. Silver-based alloys, such as silver-copper-phosphorus, or copper-phosphorus alloys are commonly used for copper brazing. 2.3. Joint Assembly: Position the copper parts in a lap joint configuration, ensuring a close fit. Fixtures or clamps can be used to secure the parts during the brazing process. 2.4. Flux Application: Apply a suitable flux to the joint area. The flux removes oxide layers, promotes wetting of the filler metal, and prevents oxidation during heating. Select a flux specifically formulated for brazing copper. 2.5. Induction Heating: Position the copper assembly within the induction coil, ensuring the joint area is within the heating zone. Adjust the induction heating system's power, frequency, and parameters based on manufacturer guidelines and the size/thickness of the copper parts. 2.6. Filler Metal Introduction: Once the joint area reaches the brazing temperature, introduce the filler metal. It can be in the form of a pre-placed filler wire or applied directly as a brazing paste or powder. The heat from the induction process melts the filler metal, allowing it to flow into the joint. 2.7. Cooling and Cleaning: After the filler metal has completely filled the joint, switch off the power and allow the joint to cool naturally. Once cooled, remove any residual flux or oxide from the brazed joint using appropriate cleaning methods. 3. Applications of Induction Brazing Copper Lap Joints 3.1. Electrical and Electronics Industry: Induction brazing is widely used in manufacturing electrical connectors, motor windings, transformers, and various electronic components that require reliable electrical conductivity and mechanical strength. 3.2. HVAC and Refrigeration: Copper tube connections in air conditioning, refrigeration, and heat exchanger systems often employ induction brazing for its efficiency, accuracy, and consistent quality. 3.3. Automotive and Aerospace: Induction brazing is utilized in the production of automotive heat exchangers, fuel systems, and aerospace components, ensuring reliable performance under demanding conditions. 3.4. Plumbing and Pipe Fittings: Copper plumbing fittings, valves, and pipe joints can be efficiently and effectively brazed using induction, providing leak-free connections and extended service life. Conclusion Induction brazing copper lap joints is a highly efficient and effective method of joining two copper pieces together. The process involves using an induction heating system to heat the joint area, melting a filler metal, and creating a strong bond between the copper pieces. This technique offers several advantages, including precise and localized heating, minimal distortion, and faster heating cycles. Induction brazing also ensures a clean and contamination-free joint, resulting in superior quality and strength. Whether you require brazing for plumbing, electronics, or any other copper applications, our skilled technicians are ready to provide reliable and durable solutions. Trust our expertise in induction brazing copper lap joints for a seamless and robust joining process that meets your specific needs. https://dw-inductionheater.com/induction-brazing-copper-lap-joints-a-reliable-and-efficient-joining-method.html?feed_id=216806&_unique_id=649ed3958717b

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction brazing copper lap joints is a highly effective method for joining copper components with precision and strength. The process involves using an induction heating system to generate heat directly within the copper material, allowing for a localized and controlled heating of the joint area. The brazing filler metal, typically a copper-based alloy, is then introduced to the heated joint, melting and flowing into the gap to create a strong, durable bond. Induction brazing offers several benefits including rapid heating, minimal distortion, and the ability to join dissimilar metals. If you are looking for a reliable and efficient method to braze copper lap joints, induction brazing is the way to go. 1. The Advantages of Induction Brazing Copper Lap Joints 1.1. Precise Heat Control: Induction brazing allows for precise and localized heating, minimizing the risk of thermal damage to the surrounding areas. This is especially important when working with sensitive copper components or assemblies with complex geometries. 1.2. Increased Efficiency: Induction heating is fast and efficient, as it directly heats the workpiece without the need for preheating the entire assembly. This results in reduced energy consumption, shorter cycle times, and increased productivity. 1.3. Stronger Joints: Induction brazing produces high-quality joints with excellent bond strength. The controlled heating process ensures uniform heating and proper filler metal flow, resulting in robust and reliable connections. 1.4. Clean and Environmentally Friendly: Induction brazing eliminates the need for open flames or torches, minimizing the risk of contamination and creating a safer working environment. Additionally, it reduces the generation of harmful fumes and pollutants, making it an eco-friendly choice. 2. The Induction Brazing Process for Copper Lap Joints 2.1. Preparation: Thoroughly clean the copper surfaces to remove any contaminants, such as dirt, grease, or oxide layers. This ensures optimal bonding and prevents defects in the joint. 2.2. Filler Metal Selection: Choose a brazing filler metal that is compatible with copper and suitable for your specific application. Silver-based alloys, such as silver-copper-phosphorus, or copper-phosphorus alloys are commonly used for copper brazing. 2.3. Joint Assembly: Position the copper parts in a lap joint configuration, ensuring a close fit. Fixtures or clamps can be used to secure the parts during the brazing process. 2.4. Flux Application: Apply a suitable flux to the joint area. The flux removes oxide layers, promotes wetting of the filler metal, and prevents oxidation during heating. Select a flux specifically formulated for brazing copper. 2.5. Induction Heating: Position the copper assembly within the induction coil, ensuring the joint area is within the heating zone. Adjust the induction heating system's power, frequency, and parameters based on manufacturer guidelines and the size/thickness of the copper parts. 2.6. Filler Metal Introduction: Once the joint area reaches the brazing temperature, introduce the filler metal. It can be in the form of a pre-placed filler wire or applied directly as a brazing paste or powder. The heat from the induction process melts the filler metal, allowing it to flow into the joint. 2.7. Cooling and Cleaning: After the filler metal has completely filled the joint, switch off the power and allow the joint to cool naturally. Once cooled, remove any residual flux or oxide from the brazed joint using appropriate cleaning methods. 3. Applications of Induction Brazing Copper Lap Joints 3.1. Electrical and Electronics Industry: Induction brazing is widely used in manufacturing electrical connectors, motor windings, transformers, and various electronic components that require reliable electrical conductivity and mechanical strength. 3.2. HVAC and Refrigeration: Copper tube connections in air conditioning, refrigeration, and heat exchanger systems often employ induction brazing for its efficiency, accuracy, and consistent quality. 3.3. Automotive and Aerospace: Induction brazing is utilized in the production of automotive heat exchangers, fuel systems, and aerospace components, ensuring reliable performance under demanding conditions. 3.4. Plumbing and Pipe Fittings: Copper plumbing fittings, valves, and pipe joints can be efficiently and effectively brazed using induction, providing leak-free connections and extended service life. Conclusion Induction brazing copper lap joints is a highly efficient and effective method of joining two copper pieces together. The process involves using an induction heating system to heat the joint area, melting a filler metal, and creating a strong bond between the copper pieces. This technique offers several advantages, including precise and localized heating, minimal distortion, and faster heating cycles. Induction brazing also ensures a clean and contamination-free joint, resulting in superior quality and strength. Whether you require brazing for plumbing, electronics, or any other copper applications, our skilled technicians are ready to provide reliable and durable solutions. Trust our expertise in induction brazing copper lap joints for a seamless and robust joining process that meets your specific needs. https://dw-inductionheater.com/induction-brazing-copper-lap-joints-a-reliable-and-efficient-joining-method.html?feed_id=216806&_unique_id=649ed3961c70e

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction Brazing Copper Lap Joints: A Reliable and Efficient Joining Method

Induction brazing copper lap joints is a highly effective method for joining copper components with precision and strength. The process involves using an induction heating system to generate heat directly within the copper material, allowing for a localized and controlled heating of the joint area. The brazing filler metal, typically a copper-based alloy, is then introduced to the heated joint, melting and flowing into the gap to create a strong, durable bond. Induction brazing offers several benefits including rapid heating, minimal distortion, and the ability to join dissimilar metals. If you are looking for a reliable and efficient method to braze copper lap joints, induction brazing is the way to go. 1. The Advantages of Induction Brazing Copper Lap Joints 1.1. Precise Heat Control: Induction brazing allows for precise and localized heating, minimizing the risk of thermal damage to the surrounding areas. This is especially important when working with sensitive copper components or assemblies with complex geometries. 1.2. Increased Efficiency: Induction heating is fast and efficient, as it directly heats the workpiece without the need for preheating the entire assembly. This results in reduced energy consumption, shorter cycle times, and increased productivity. 1.3. Stronger Joints: Induction brazing produces high-quality joints with excellent bond strength. The controlled heating process ensures uniform heating and proper filler metal flow, resulting in robust and reliable connections. 1.4. Clean and Environmentally Friendly: Induction brazing eliminates the need for open flames or torches, minimizing the risk of contamination and creating a safer working environment. Additionally, it reduces the generation of harmful fumes and pollutants, making it an eco-friendly choice. 2. The Induction Brazing Process for Copper Lap Joints 2.1. Preparation: Thoroughly clean the copper surfaces to remove any contaminants, such as dirt, grease, or oxide layers. This ensures optimal bonding and prevents defects in the joint. 2.2. Filler Metal Selection: Choose a brazing filler metal that is compatible with copper and suitable for your specific application. Silver-based alloys, such as silver-copper-phosphorus, or copper-phosphorus alloys are commonly used for copper brazing. 2.3. Joint Assembly: Position the copper parts in a lap joint configuration, ensuring a close fit. Fixtures or clamps can be used to secure the parts during the brazing process. 2.4. Flux Application: Apply a suitable flux to the joint area. The flux removes oxide layers, promotes wetting of the filler metal, and prevents oxidation during heating. Select a flux specifically formulated for brazing copper. 2.5. Induction Heating: Position the copper assembly within the induction coil, ensuring the joint area is within the heating zone. Adjust the induction heating system's power, frequency, and parameters based on manufacturer guidelines and the size/thickness of the copper parts. 2.6. Filler Metal Introduction: Once the joint area reaches the brazing temperature, introduce the filler metal. It can be in the form of a pre-placed filler wire or applied directly as a brazing paste or powder. The heat from the induction process melts the filler metal, allowing it to flow into the joint. 2.7. Cooling and Cleaning: After the filler metal has completely filled the joint, switch off the power and allow the joint to cool naturally. Once cooled, remove any residual flux or oxide from the brazed joint using appropriate cleaning methods. 3. Applications of Induction Brazing Copper Lap Joints 3.1. Electrical and Electronics Industry: Induction brazing is widely used in manufacturing electrical connectors, motor windings, transformers, and various electronic components that require reliable electrical conductivity and mechanical strength. 3.2. HVAC and Refrigeration: Copper tube connections in air conditioning, refrigeration, and heat exchanger systems often employ induction brazing for its efficiency, accuracy, and consistent quality. 3.3. Automotive and Aerospace: Induction brazing is utilized in the production of automotive heat exchangers, fuel systems, and aerospace components, ensuring reliable performance under demanding conditions. 3.4. Plumbing and Pipe Fittings: Copper plumbing fittings, valves, and pipe joints can be efficiently and effectively brazed using induction, providing leak-free connections and extended service life. Conclusion Induction brazing copper lap joints is a highly efficient and effective method of joining two copper pieces together. The process involves using an induction heating system to heat the joint area, melting a filler metal, and creating a strong bond between the copper pieces. This technique offers several advantages, including precise and localized heating, minimal distortion, and faster heating cycles. Induction brazing also ensures a clean and contamination-free joint, resulting in superior quality and strength. Whether you require brazing for plumbing, electronics, or any other copper applications, our skilled technicians are ready to provide reliable and durable solutions. Trust our expertise in induction brazing copper lap joints for a seamless and robust joining process that meets your specific needs. https://dw-inductionheater.com/induction-brazing-copper-lap-joints-a-reliable-and-efficient-joining-method.html?feed_id=216806&_unique_id=649ed39573de9

What Is Induction Heating Coil&Inductor?

What is induction heating coil & inductor? The varying magnetic field required for induction heating is developed in the induction heating coil via the flow of AC (alternating current) in the coil. The coil can be made in many shapes and sizes to custom fit a specific application. The coils can range from tiny coils made of copper tubing used for precise heating of extremely small parts in applications such as soldering and ferrule heating to large coil assemblies of copper tubing used in applications such as strip metal heating and pipe heating. What is the importance of the induction heating coil (inductor)? The induction coil design is one of the most important aspects of an induction heating system. The coil is a custom design to give your work piece or part the proper heating pattern, maximize efficiency of the induction heating power supply’s load matching system, and to accomplish these tasks while still permitting ease of loading and unloading your part.

Induction Preheating Steel Tubes

Objective Induction preheating steel tubes with diameters of 14mm, 16mm, and 42mm (0.55”, 0.63”, and 1.65”). A 50mm (2″) length of the tube much be heated to 900°C (1650°F) in under 30 seconds.

Equipment DW-UHF-6KW-III handheld induction heater Materials • Steel tubes with ODs: 14mm, 16mm and 42mm (0.55”, 0.63”, and 1.65”) • Wall thicknesses: 1mm, 2mm, and 2mm (0.04″, 0.08″, 0.08″) Key Parameters Power: 5 kW for 42mm tube, 3 kW for 14 and 16 mm tubes Temperature: 1740°F (950°C) Time: 26 sec.

Process:

1. Insert steel tube into the coil.
2. Apply induction heat for 26 seconds.
3. Remove the tube from the coil.

Results/Benefits: The desired preheating temperature was achieved for less than 30 seconds for the three different steel tubes. Our 5 kW induction system can be used for successfully preheating of steel tubes with different diameters and thicknesses.

https://dw-inductionheater.com/induction-preheating-steel-tubes.html?feed_id=216661&_unique_id=649db9b93f46b

Why Choose Induction Heating and what are its advantages

Why Choose Induction Heating and what are its advantages

Why choose induction heating over convection, radiant, open flame or another heating method? Here's a short summary of the major advantages that modern solid state induction heating offers for lean manufacturing:

Optimized Consistency

Induction heating eliminates the inconsistencies and quality issues associated with open flame, torch heating and other methods. Once the system is properly calibrated and set up, there is no guess work or variation; the heating pattern is repeatable and consistent. With modern solid state systems, precise temperature control provides uniform results; power can be instantly turned on or shut off. With closed loop temperature control, advanced induction heating systems have the capability to measure the temperature of each individual part. Specific ramp up, hold and ramp down rates can be established & data can be recorded for each part that is run.

Maximized Productivity

Production rates can be maximized because induction works so quickly; heat is developed directly and instantly (>2000º F. in < 1 second) inside the part. Startup is virtually instantaneous; no warm up or cool down cycle is required. The induction heating process can be completed on the manufacturing floor, next to the cold or hot forming machine, instead of sending batches of parts to a remote furnace area or subcontractor. For example, a brazing or soldering process which previously required a time-consuming, off-line batch heating approach can now be replaced with a continuous, one-piece flow manufacturing system.

Improved Product Quality

With induction, the part to be heated never comes into direct contact with a flame or other heating element; the heat is induced within the part itself by alternating electrical current. As a result, product warpage, distortion and reject rates are minimized. For maximum product quality, the part can be isolated in an enclosed chamber with a vacuum, inert or reducing atmosphere to eliminate the effects of oxidation.

Extended Fixture Life

Induction heating rapidly delivers site-specific heat to very small areas of your part, without heating any surrounding parts. This extends the life of the fixturing and mechanical setup.

Environmentally Sound

Induction heating systems do not burn traditional fossil fuels; induction is a clean, non-polluting process which will help protect the environment. An induction system improves working conditions for your employees by eliminating smoke, waste heat, noxious emissions and loud noise. Heating is safe and efficient with no open flame to endanger the operator or obscure the process. Non-conductive materials are not affected and can be located in close proximity to the heating zone without damage.

Reduced Energy Consumption

Tired of increasing utility bills? This uniquely energy-efficient process converts up to 90% of the energy expended energy into useful heat; batch furnaces are generally only 45% energy-efficient. And since induction requires no warm-up or cool-down cycle, stand-by heat losses are reduced to a bare minimum. The repeatability and consistency of the induction process make it highly compatible with energy-efficient automated systems. High frequency induction machines and induction heating technology is currently the highest heating efficiency of the metallic materials, the fastest speed, and low power consumption of environmental protection. It has been widely used in various industries on the thermal processing of the metal material, heat treatment, hot assembly and welding, melting process. It can not only heating the workpiece as a whole, but also on the relevance of the workpiece local heating; deep through the heat of the workpiece can be realized, to focus only on its surface, the surface heating; not only the direct heating of the metal material, but also on non-metallic material indirect heating. And so on. Thus, induction heating technology is more widely used in all walks of life. Local heating of the surface of the workpiece with the induced current heat treatment process. This heat treatment process commonly used in the surface hardening, but also can be used for partial annealing or tempering, and sometimes also used for the overall quenching and tempering. The early 1930s, the United States, the Soviet Union has applied to the induction heating method for surface hardening of parts. With industrial development, induction heating, heat treatment technology continue to improve, continue to expand the range of applications. Basic principles: the workpiece into the inductor (coil), and when the sensors pass into the alternating current of a certain frequency, alternating magnetic field is generated around. The electromagnetic induction effect of the alternating magnetic field so that the induction current the workpiece generated within a closed ─ ─ vortex. Induced currents are very unevenly distributed in the cross section of the workpiece, a high current density of the workpiece surface, the inwardly gradually decreases, this phenomenon is called the skin effect. The high current density of the workpiece surface energy into thermal energy, so that the temperature of the surface layer is increased, i.e. the surface heating. The current frequency is higher, the current density of the workpiece surface and the internal differential is the greater, the heating layer is thinner. Rapid cooling, the temperature of the heating layer over the temperature of the critical point of steel surface hardening can be achieved. Classification: according to the frequency of the alternating current, the induction heating and heat treatment is divided into UHF, HF, RF, MF, working frequency. (1) ultra-high frequency induction heating treatment used in the current frequency up to 27 MHz, the heating layer is extremely thin, only about 0.15 mm, can be used for complex shapes such as circular saws and workpiece thin surface hardening. ② high-frequency induction heating heat treatment is usually used in current frequency of 200 to 300 kHz, the depth of the heating layer is 0.5 to 2 mm can be used for the gear, cylinder sleeve, cam, shaft and other parts of the surface quenching. ③The  radio induction heating heat treatment with the current frequency of 20 to 30 kHz, with a super audio induced current small modulus gear heating, the heating layer roughly along the tooth profile distribution, the pure fire better performance. 4 MF (Medium Frequency) induction heating of the heat treatment using the current frequency is generally from 2.5 to 10 kHz, the depth of the heating layer is 2 to 8 mm, and more for large modulus gear, having a larger diameter shaft and cold roll the workpiece such as surface hardening. ⑤ power frequency induction heating heat treatment used in the current frequency of 50 to 60 Hz, the depth of the heating layer is 10 to 15 mm, can be used for the surface hardening of large workpieces. Characteristics and application: The main advantage of induction heating: ① having overall heating workpiece deformation is small, small power consumption. The ② pollution. ③ heating speed, the workpiece surface oxidation and decarbonization lighter. ④ surface hardened layer can be adjusted as needed, easy to control. (5) heating equipment can be installed in the mechanical processing production line, easy to realize mechanization and automation, easy to manage, and can reduce the transportation, saving manpower, improve production efficiency. ⑥ hardened layer martensite smaller, hardness, strength, toughness, are higher. ⑦ surface hardening of the workpiece surface greater compression internal stress, higher workpiece anti-fatigue breaking ability. The induction heating heat treatment also has some drawbacks or disadvantages. Compared with flame hardening, induction heating equipment is more complex, and adaptability to poor, difficult to guarantee the quality of some of the complex shape of the workpiece. The induction heater is more complex, once the cost of inputs is relatively high, interchangeability and adaptability of the induction coil(inductor) is poor, can not be used for some complex shape of the workpiece. But obviously,the advantages outweighed the disadvantages. Therefore, the induction heating is a better choice of metalworking for replacing coal heating, oil heating, gas heating, electric cooker, electric oven heating and other heating methods.

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Applications: Induction heating is widely used for the surface hardening of the gears, shafts, crankshafts, cams, rollers, etc. of the workpiece, the purpose is to improve the abrasion resistance and anti-fatigue breaking capability of these artifacts. Automobile rear axle using induction heating surface hardening, fatigue design load cycles increases by about 10 times more than the quenched and tempered. Induction heating surface hardening of the workpiece material is generally in the carbon steel. In order to meet the special needs of some of the workpiece has been developed for induction heating surface hardening dedicated low hardenability steel. High-carbon steel and cast iron workpiece can also be used induction heating surface hardening. The quenching medium commonly Water or polymer solution. Equipment: Induction Heat Treatment Equipment power equipment, quenching machine and sensor. The main role of the power supply apparatus is suitable output frequency of the alternating current. The high-frequency current power supply tube high-frequency generator and two SCR inverter. IF current power supply generator sets. General power supply can only output a frequency current, some equipment can change the current frequency, directly with the 50 Hz power frequency current induction heating. Selection: the depth of the induction heating device selection and the workpiece requires heating layer. Heating the deep layer of the workpiece, using the current low frequency power supply apparatus; the heating layer shallow workpiece, the current high frequency power supply apparatus should be used. Select other conditions of the power supply is the power of the device. Heating surface area increases, the electrical power required by the corresponding increase. When the heating surface area is too large, or when insufficient power supply, the method may be continuously heated, so that the relative movement of workpiece and the sensor, the front heating, behind cooling. But the best, or the entire heating surface heating. This can use the the workpiece core section waste heat so that the hardened surface layer tempering so that the process is simplified, and also saving energy. The main role of the induction heating machine is the workpiece positioning and necessary movement. It should also be accompanied by the quenching media device. Quenching machine can be divided into standard machine tools and special machine tools, the former applies to the general workpiece, which is suitable for mass production of complex workpieces. Inductive heating of heat treatment, in order to ensure the quality of the heat treatment and to improve thermal efficiency, it is necessary according to the shape of the workpiece and requirements, design and manufacturing structure appropriate sensors. Common sensor heating the outer surface of the sensor, inner hole heating sensor plane heat sensor, universal heating sensor, a special type of heating sensor, a single type of heating sensors, the composite heated sensor, smelting furnace .    

RPR Induction Pipeline Coating Removal

RPR Induction Pipeline Coating Removal-Induction Rust Paint Coating Removal

How Induction Stripping Works?

Induction stripping is a hot surface preparation process.An induction generator sends alternating current through an induction coil, which generates an electromagnetic field. This field induces currents that are converted into heat in contact with conducting materials such as steel. The heat is generated beneath the coating, causing the coating to peel rapidly. This method is suitable for treating flat or curved surfaces on the jobsite and does not require any confinement. The induction stripping system will strip paint, other coatings, heavy rust, bacterial corrosion and oil and grease electrically conductive surfaces (ferromagnetic steel) breaking the interfacial bonding between the material and the substrate etch residues, induction heating localized and controlled which consumes minimal energy. HLQ simplifies your coatings removal needs with yet another revolutionary technology: Induction Stripping! HLQ’s induction stripping equipment removes your toughest coatings from steel structures with no noise or secondary waste—getting right down to the steel.

If you have ever wished for a magic wand to solve your coatings removal headaches, HLQ has the next best thing. HLQ technician can wave our induction wand over your coating catastrophe and dis-bond some of the hardest to remove coatings at rates that are up to 10 times faster than competing technologies like sandblasting.It’s not magic, but our induction stripping technology is a close second! When HLQ technicians move our induction head over a steel surface, it creates sufficient heat (typically 300 to 400 degrees) to quickly unbond most coatings from tanks, tankers, pipelines, ships and offshore platforms, allowing coatings (up to 1-inch thick) to be removed in sheets.

RPR Heat Induction Coating Removal

RPR Heat Induction coating removal works by the principle of induction. Heat is generated in the steel substrate and the bond at the steel and coating interface is broken. The coating is then removed entirely without disintegrating and completely free from contaminating agents, i.e.. blast media. This makes disposal and recycling of waste easier and more cost effective.   With minimum power consumption even the thickest and hardest coatings can be completely removed. RPR Heat Induction is faster than conventional methods. A silent method of coating removal means that our engineers can operate day or night with no noise pollution. Because of the many advantages of our induction heating process, we’ve been able to provide a wide range of Alliance customers with the service they need. We’ve worked with customers in industries such as:

• Oil & gas
• Financial
• Food & beverage processing
• Retail and food services
• Marine
• Hotels & hospitality
• Commercial pools and aquariums

HLQ’s jaw-dropping induction dis-bonding process removes most coating types, including:

• Coal Tar Epoxy
• Polyethylene
• Fiberglass

• Anti-skid
• Rubber
• Chartek fireproofing or other intumescent coatings

Faster, Quieter, Cleaner, Safer Surface Preparation

Some might say induction stripping is the “quick and dirty” way to get the job done, but truthfully it’s quick, and not messy at all. Because induction stripping creates no secondary waste, cleanup is simplified. Dealing with sheets or strips of coating is infinitely easier than dealing with blast media and dust.

In many cases, containment can be simplified or eliminated altogether. Imagine eliminating a costly scaffolding and containment project and replacing it with a snorkel lift and a drop cloth! Other trades can work in close proximity to HLQ’s induction stripping activities because it is a very quiet process that will not create obnoxious noises that disrupt the productivity of other contractors you may have working on your project. Our induction stripping equipment has no moving parts, making our process much safer than hydro-blasting or sandblasting for your employees, other contractors, customers and passersby. RPR induction removes paint, coatings, thick rust, bacterial corrosion and oil & grease residues from electrically conductive surfaces (steel, etc.) by breaking the interfacial bonding between the material to be removed and the substrate using controlled, localized induction heating with a mini- mum consumption of energy.

The induction heating principle

The RPR induction generator sends alternating current through an induction heating coil, which gener- ates an electro-magnetic field. This magnetic field induces eddy currents in a conductive mate- rial like steel. Due to the resistance of the steel, these currents are converted to heat = induction heating. The heat is generated below the coat- ing, resulting in quick and clean disbonding. The RPR system is ideal for the removing paint, rust, and other coatings (vulcanized rubber, fire protectant, epoxies, etc. with control possibili- ties for the following functions: • Energy consumption • Disbonding temperature range • Heat penetration • Removal speed With above setting possibilities, RPR delivers unequalled performance and is the system of choice for cost-effective, safe and environmentally friendly surface coating removal from steel substrates. RPR is ideal for: marine, tanks, offshore and land-based pipelines

Induction Coating Machine & Induction Paint Stripping System & RPR Induction System

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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.