induction hardening applications

Induction heating is a non contact heating process which uses the principle of electromagnetic induction to produce heat inside the surface layer of a work-piece. Ambrell has offered cutting-edge hardening solutions since 1986. endstream endobj startxref Induction hardening is a process in which the heat is generated directly in the workpiece. Induction hardening uses induced heat and rapid cooling (quenching) to increase the hardness and durability of steel. A medium frequency is overlaid with a high one so that both act upon the material simultaneously at a uniform depth. The current generated flows predominantly in the surface layer, the depth of this laye… Full integration: SYSTEM LINE generators, designed for integration in machines and fully automated systems (MF and HF 5 – 150 kW). When placing a product in that field, an electric voltage is produced which results in an opposite alternating current. Implications of induction hardening O ne of the most common applications of induction heat treat - ment is the hardening of steels, cast irons, and powder metal - lurgy materials. There are two mechanisms of energy absorption: generation of close-loop (eddy) currents inside the body which cause heating due to electrical resistance of the body material After quenching, the steel undergoes tempering, a low-temperature heat treatment process, to reach the desired hardness / toughness ratio. Treating the steel through tempering reduces the hardness in the material and increases its toughness. Basic of Induction Heating; Advantages of Induction Heating; induction annealing process; Applications. Induction hardening is the process by which metal is heated then rapidly cooled in order to increase the hardness of the material. Induction hardening You are here: Home 1 / Applications 2 / Induction hardening The induction heating is one of the most energy efficient processes for surface heat treatment with high productivity rate, real time and individual process control. Components of various geometries can be induction … Induction Heating is a Contactless Heating Method of bodies, which absorb energy from an Alternating Magnetic Field, generated by Induction Coil (Inductor). eldec offers energy sources with the latest converter technology in three frequency ranges: With Simultaneous Dual Frequency, also known as SDF, eldec offers an additional  method that is used especially for workpieces with complex shapes. Gearbox and Hydraulic Valve Parts. Hardening. The mid-range: Energy sources with single or multiple outputs as a standalone solution or for integration into systems (MF and HF 5 – 225 kW). All in one: Mobile energy sources with integrated active cooler and intuitive touchscreen operation (MF and HF 20 – 70 kW). In induction hardening, Barkhausen Noise Analysis is used to verify the induction hardening coil’s location or automatically sort the samples that may have missed the hardening process. Induction Hardening Applications The heat treating hardening process is utilized in various industries, including transportation, aerospace, and energy. Radyne Induction Heating Systems match your mill speed, require minimal maintenance, provide uniform metallurgical quality, and are built for a range of applications from coating and heat treatment. This enables a wide range of heating applications to be undertaken. The induction hardening is a heat treatment for surface hardening, mainly used for complicated shaped workpieces or for partially hardening of specific parts of an item. How induction hardening works. 272 0 obj <>stream These methods take considerably longer and require significantly more energy to produce the desired hardness. Induction hardening offers users outstanding control over of the hardening process. Induction hardening is used to strengthen a specific area of a part. The primary application of this induction method is the hardening of steel. Forging with induction heating Forging is the process to make different shape of the component by heating and hammering or by application of contact forces. With the precision frequency adjustment, even the most demanding jobs can be completed with ease. The power supply is designed to optimally match the frequency with the application according to the requirements of the workpiece. One or many induction coils are used to generate and target an alternating magnetic field. Hardening crankshafts involves consideration of 4 different heating zones - pins, journals, flanges, and shaft - with unique characteristics. Induction Hardening. Ideal hardening results can only be achieved by perfectly matching a precisely controlled energy source with an optimum inductor design. Induction heating applications Induction Hardening Equipment has been used for many years in the automotive, aerospace and general engineering components industries. ), as described in the DIN EN 100083 industry norm. The primary application of this induction method is the hardening of steel. Hardening is a process of heating followed by cooling generally fast for increase hardness and mechanical strength of steel. Every machine is completely inspected and tested to ensure optimum power and heat settings. This magnetic field produces eddy currents in the metal, which heat the workpiece up to the desired temperature. Typically, less than 5% of the mass needs be targeted to accomplish the required properties. Typical Applications. Induction hardening is a heat treatment process carried out to enhance the mechanical properties in a localised area of a ferrous component. One or many induction coils are used to generate and target an alternating magnetic field. Higher frequencies produce thinner skins. Induction Heating. Induction Annealing; Induction Bonding; Induction Brazing; Custom Applications; Induction Forging; Induction Hardening; Induction Heating; Induction Melting; Induction Preheating; Pipe and Tube; Products. Then coal is transferred into the part from a CO-emitting medium through the part’s surface. With traditional heat treatments such as flames, ovens, or by convection, heat is applied to the part by heating up the surface layer. Furthermore, they do not have to be kept running when not in use, unlike surface hardening furnaces.The use of induction is very energy efficient since only a small portion of the material is heated. Induction is a no-contact process that quickly produces intense, localized and controllable heat. Hardening Steel Crankshafts Most crankshafts are manufactured in cast steel; some high-end crankshafts are produced with forged steel. With a conventional method (or if we induction hardened the entire length for that matter), there would be significantly more warpage. Induction hardening . The results are outstanding, achieving accurate hardening results even on complex pieces with contours. As with induction hardening, the goal is to harden the outer layer of workpieces. Induction hardening is a form of heat treating where a metal part is heated by induction and then quenched. The hardening depth in the workpiece is controlled, very precisely, by adjusting the electrical power output of the induction machine and the frequency of the inductor / coil current. The thickness of the heated layer from the surface of the metal to some point below the surface is inversely proportional to the frequency of the applied alternating current. Case hardening the surface of steel increases the wear resistance of the component without reducing the ductility of the bulk of the material. used in induction hardening are SAE 4140, 4150, 4340, 5150, 5140, and 52100. The surface of this 1055 steel shaft is … Induction Hardening Equipment. Induction hardening, using induction heating and quenching, provides an economical way to process shafts, gears, bearings, yokes, … The most popular steel utilized for parts to be induction hardened is 1045. The number of rejected or deformed parts is also minimized with this process.Why eldec?eldec offers a wide range of compact generators for induction hardening that provide customers with the highest-quality in terms of performance. Engine. Click to learn more about Wire, Rod, Cable, and Tube Processing Read More This can be done by an informal note to: EMAG GmbH und Co KG, Austraße 24, 73084 Salach, Germany or communications@emag.com. This process is perfect for metal with a carbon content of more than 0.3%, particularly hardened steel with a low alloy content (C34, C35, C60, etc. eldec's experienced engineers custom design the induction coils to meet customer unique specifications, including single turn, two-turn, face-heating, clamshell, and clamp inductors. Induction hardening is generally used as a peripheral layer hardening process where the hardening depth and other parameters are manipulated through the frequency of the inductor/coil current. Immediately after heating, the component then goes through a quenching process using water, oil, or an emulsion. By placing a conductive material into a strong alternating magnetic field, electric current can be made to flow in the material thereby creating heat due to the I R losses in the material. The sky is the limit: Customized energy sources with single or multiple outputs and a wealth of power and frequency combinations (LF, MF, HF, DFG, SDF 20 – 3000 kW). Not only does eldec offer hardening systems, but they also offer a wide range of generators, tools and brazing and heating systems. Induction hardening Treatment is favored for parts that are subject to heavy loading. Multi power: Plug-in expandable energy source for precise integration into systems (MF 5 – 30 kW). In magnetic materials, further heat is generated below the curie point due to hysteresislosses. We also have metallurgical sectioning ability to test accurately hardened depths and extents. Home » Applications » Metal industry » Induction hardening. Among other workpieces, such components as camshafts, crankshafts, gears, transmission shafts, ball studs, pins, Typical applications include axles, saw blades, shafts, stampings, spindles, gears and most symmetrical parts. 1. In case hardening the workpieces are hardened by carburization. This minimizes deformities in the workpiece and ensures the efficiency of the process. Induction hardening and heat treating are ideal for a wide variety of applications in the transportation, aerospace, and energy industries, for processes such … hÞb```¢PV^-Ad`CË Ê.‚Žš97w}ҙí«|œ3|OâW‡ÿÏöXÛìW˜uÚ(k÷Ö׿–ò¿Ø®S¹ò¬ÿޕ¼,\k×00ü:áÑ^9¦—30¿rÝ)gåºHo´[-wxIôÅ7V¾Ñ¯ŽD_|eãKCÎfIìFˆØ8 µ­ƒ¡‚•:X. In this scanning induction hardening simulation, the steel shaft is heated by eddy currents, provided by a moving, two-turn copper coil. Carbon ste… This guarantees the component is heated at a consistent temperature across the entire part to ensure even surface hardness. Induction Brazing Brazing is a method in which two or more like or unlike are joined together, with the help of heat and braze material. To ensure that the perfect solution is discovered for any application, the MIND range of machines have been specially designed and manufactured to meet customer requirements. A number of applications and items can benefit from the heat treatment hardening process described above. Induction Heating Applications RDO Induction's mission is to provide our customers with superior products and support for a variety of induction heating applications. High productivity: Hardening quantity can be choosen according to your actual needs, segmentally and collectively in single and double station. Induction Hardening Applications. The modular ELO-INDIVIDUAL system solution is designed for cost-efficient induction applications with shorter cycle times, a high degree of integration, frequently switching hardening tasks and special solutions. Hardening is the process of heating the material above 900°C temperature followed by quenching. 0 Examples include machine tools, … The principal advantage of this type of heat treatment is that the material quickly reaches the desired temperature to produce hardened metal parts. The maximum hardness of a steel grade obtained through the hardening process gives the material a low toughness. The steel is heated to over 880 °C to become austenitic. Induction hardened shafts lend themselves very well to most torsional applications because induction hard-ening increases the hardness near the surface where it is most needed and it leaves the surface in compression, which improves fatigue life. The presence of compressive residual stresses of appreciable magnitude that is quite typical in induction surface hardening applications is often sufficient in preventing “opening” slightly liquated grain boundaries. The process is very demanding on the equipment and the inductor used. Induction heating machines have minimal space requirements and can be easily integrated into manufacturing processes and production lines. Service Generators: +1-248-364-4750communications@emaggroup.de, Service Hardening Systems +49 7443 9649-22communications@emaggroup.de, Service Generators +49 7443 9649-33communications@emaggroup.de. 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. Induction hardening uses induced heat and rapid cool- ing (quenching) to increase the hardness and dura-bility of steel. The method is suitable for 100% inspection and provides feedback on the induction hardening process in a few seconds. Even though the top and bottom of the gear teeth are at different distances from the inductor, a smooth and precise hardness layer can be achieved. hÞbbd``b`v%@‚i`y$Ø[AہWy$J­„À á5…‰‘¡¤‘ ñŸñÑO€ / %PDF-1.5 %âãÏÓ Typical applications of induction hardening include gears, shafts, axles, cam lobes, stampings, and spindles, mostly symmetrical parts. This safe heating method enjoys a multitude of applications, including the manufacture of steel shafts and axels, and can be used across a range of industries. 263 0 obj <>/Filter/FlateDecode/ID[<0F247B38338A404988A023EFD66F2F12><241ED11A68658D4AB0119D5E3185C7A4>]/Index[252 21]/Info 251 0 R/Length 71/Prev 1146436/Root 253 0 R/Size 273/Type/XRef/W[1 2 1]>>stream 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. Allows use of Low Cost Steels such as 1045. Induction hardening is performed on just these surfaces, a total of 4” length. Whether your process involves shaft hardening, gear or teeth hardening, we have the right induction heating solution for your application. Induction hardening can be used for a wide range of parts, and prom-inent examples are discussed in separate articles in this Volume. It is a very effective and attractive method in the manufacturing of steel shafts, components, and other metal parts across a range of industries. Small, red, strong: Cost-effective energy sources with a single output and extremely easy, intuitive operation (MF and HF 5 – 150 kW). %%EOF Additionally, induction heating can be very precisely controlled via the power, frequency, and inductor geometry. Induction hardening offers significant advantages over traditional methods for heat-treating steel, alloy, and other metal parts. Frequently, steel and stainless steel components require induction hardening to provide optimum performance and long service. Applications. This magnetic field produces eddy currents in the metal, which … This application is perfect for the process of manufacturing cogs and gears. Transmission. When a shaft is loaded torsionally, the shear stress is highest at the surface and zero at the center. The braze material temperature should be lower than the parents materials. This cools the metal until martensitic transformation occurs, producing a hardened surface that is tougher than the base metal. I may withdraw my consent at any time. Shafts, gears, armatures, sprockets and other components can all be hardened using this induction process. Induction hardening, using induction heating and quenching, provides an economical way to process shafts, gears, bearings, yokes, spindles, sprockets, wire, tube, pipe or other parts. Induction hardening In inductive hardening or induction hardening, an alternating current is driven through a coil-shaped conductor, thereby creating a magnetic field. Our sophisticated training concept gives you the opportunity to have your eldec system operators comprehensively trained. Hardening is usually increasing the hardness. Description. Induction hardening, by contrast, offers extremely short heating times. The resultant hardened area improves the wear and fatigue resistances along with strength characteristics. Single piece, surface hardening of selective areas. Induction is a no-contact process that quickly produces intense, localized and controllable heat. 252 0 obj <> endobj Rotation is essential for even and equal heat distribution on some components. Induction Hardening Applications Include. Induction annealing and normalizing Reduces hardness, improves ductility and relieves internal stresses. With induction, only the part to be hardened is heated. Our engineering expertise in developing induction hardening solutions has been applied by many automotive manufacturers worldwide. The use of induction for hardening will allow for greatly increased production rates versus furnace or flame heat treating and can lend itself to fully automated processes. , oil, or an emulsion hardness and durability of steel hardening applications the heat treatment is favored for to! 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