induction hardening applications

Ambrell has offered cutting-edge hardening solutions since 1986. Induction hardening is a process in which the heat is generated directly in the workpiece. Induction heating applications I may withdraw my consent at any time. Induction Hardening Equipment has been used for many years in the automotive, aerospace and general engineering components industries. It is a very effective and attractive method in the manufacturing of steel shafts, components, and other metal parts across a range of industries. How induction hardening works. This minimizes deformities in the workpiece and ensures the efficiency of the process. 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. Hardening is the process of heating the material above 900°C temperature followed by quenching. Induction hardening, using induction heating and quenching, provides an economical way to process shafts, gears, bearings, yokes, … 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. Examples include machine tools, … Induction hardening is a heat treatment process carried out to enhance the mechanical properties in a localised area of a ferrous component. Immediately after heating, the component then goes through a quenching process using water, oil, or an emulsion. hÞbbd``b`v%@‚i`y$Ø[AہWy$J­„À á5…‰‘¡¤‘ ñŸñÑO€ / Induction hardening is performed on just these surfaces, a total of 4” length. When placing a product in that field, an electric voltage is produced which results in an opposite alternating current. Induction hardening offers significant advantages over traditional methods for heat-treating steel, alloy, and other metal parts. The process is very demanding on the equipment and the inductor used. In magnetic materials, further heat is generated below the curie point due to hysteresislosses. 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). endstream endobj startxref Induction hardening, by contrast, offers extremely short heating times. Hardening. Applications. 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. Higher frequencies produce thinner skins. The principal advantage of this type of heat treatment is that the material quickly reaches the desired temperature to produce hardened metal parts. These methods take considerably longer and require significantly more energy to produce the desired hardness. Induction hardening is a form of heat treating where a metal part is heated by induction and then quenched. Allows use of Low Cost Steels such as 1045. 252 0 obj <> endobj Induction hardening In inductive hardening or induction hardening, an alternating current is driven through a coil-shaped conductor, thereby creating a magnetic field. Induction hardening uses induced heat and rapid cooling (quenching) to increase the hardness and durability of steel. Induction annealing and normalizing Reduces hardness, improves ductility and relieves internal stresses. The primary application of this induction method is the hardening of steel. Typically, less than 5% of the mass needs be targeted to accomplish the required properties. Case hardening the surface of steel increases the wear resistance of the component without reducing the ductility of the bulk of the material. 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. Typical applications of induction hardening include gears, shafts, axles, cam lobes, stampings, and spindles, mostly symmetrical parts. 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 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. In this scanning induction hardening simulation, the steel shaft is heated by eddy currents, provided by a moving, two-turn copper coil. 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. Typical Applications. 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. This cools the metal until martensitic transformation occurs, producing a hardened surface that is tougher than the base metal. Hardening is a process of heating followed by cooling generally fast for increase hardness and mechanical strength of steel. Single piece, surface hardening of selective areas. With a conventional method (or if we induction hardened the entire length for that matter), there would be significantly more warpage. One or many induction coils are used to generate and target an alternating magnetic field. 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. Induction hardening offers users outstanding control over of the hardening process. Frequently, steel and stainless steel components require induction hardening to provide optimum performance and long service. Description. A number of applications and items can benefit from the heat treatment hardening process described above. 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. This magnetic field produces eddy currents in the metal, which … Induction is a no-contact process that quickly produces intense, localized and controllable heat. Induction is a no-contact process that quickly produces intense, localized and controllable heat. Carbon ste… The resultant hardened area improves the wear and fatigue resistances along with strength characteristics. Among other workpieces, such components as camshafts, crankshafts, gears, transmission shafts, ball studs, pins, 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. 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. Whether your process involves shaft hardening, gear or teeth hardening, we have the right induction heating solution for your application. The surface of this 1055 steel shaft is … The primary application of this induction method is the hardening of steel. Click to learn more about Wire, Rod, Cable, and Tube Processing 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 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. Induction Hardening Applications Include. %%EOF Engine. 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. All in one: Mobile energy sources with integrated active cooler and intuitive touchscreen operation (MF and HF 20 – 70 kW). This magnetic field produces eddy currents in the metal, which heat the workpiece up to the desired temperature. Induction hardening Treatment is favored for parts that are subject to heavy loading. This enables a wide range of heating applications to be undertaken. Small, red, strong: Cost-effective energy sources with a single output and extremely easy, intuitive operation (MF and HF 5 – 150 kW). The most popular steel utilized for parts to be induction hardened is 1045. %PDF-1.5 %âãÏÓ As with induction hardening, the goal is to harden the outer layer of workpieces. Full integration: SYSTEM LINE generators, designed for integration in machines and fully automated systems (MF and HF 5 – 150 kW). 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. The power supply is designed to optimally match the frequency with the application according to the requirements of the workpiece. Typical applications include axles, saw blades, shafts, stampings, spindles, gears and most symmetrical parts. One or many induction coils are used to generate and target an alternating magnetic field. Induction Heating. 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. Induction hardening . The steel is heated to over 880 °C to become austenitic. Additionally, induction heating can be very precisely controlled via the power, frequency, and inductor geometry. Transmission. With induction, only the part to be hardened is heated. ), as described in the DIN EN 100083 industry norm. This can be done by an informal note to: EMAG GmbH und Co KG, Austraße 24, 73084 Salach, Germany or communications@emag.com. 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 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. 1. Hardening Steel Crankshafts Most crankshafts are manufactured in cast steel; some high-end crankshafts are produced with forged steel. Induction heating machines have minimal space requirements and can be easily integrated into manufacturing processes and production lines. This application is perfect for the process of manufacturing cogs and gears. When a shaft is loaded torsionally, the shear stress is highest at the surface and zero at the center. 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). Induction Hardening Applications. 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. Then coal is transferred into the part from a CO-emitting medium through the part’s surface. A medium frequency is overlaid with a high one so that both act upon the material simultaneously at a uniform depth. In case hardening the workpieces are hardened by carburization. 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. The method is suitable for 100% inspection and provides feedback on the induction hardening process in a few seconds. Induction Hardening. Our sophisticated training concept gives you the opportunity to have your eldec system operators comprehensively trained. The braze material temperature should be lower than the parents materials. Components of various geometries can be induction … With traditional heat treatments such as flames, ovens, or by convection, heat is applied to the part by heating up the surface layer. 272 0 obj <>stream This guarantees the component is heated at a consistent temperature across the entire part to ensure even surface hardness. Shafts, gears, armatures, sprockets and other components can all be hardened using this induction process. Induction hardening is the process by which metal is heated then rapidly cooled in order to increase the hardness of the material. Induction Heating Applications RDO Induction's mission is to provide our customers with superior products and support for a variety of induction heating applications. Every machine is completely inspected and tested to ensure optimum power and heat settings. Ideal hardening results can only be achieved by perfectly matching a precisely controlled energy source with an optimum inductor design. Gearbox and Hydraulic Valve Parts. The results are outstanding, achieving accurate hardening results even on complex pieces with contours. Induction hardening uses induced heat and rapid cool- ing (quenching) to increase the hardness and dura-bility of steel. The maximum hardness of a steel grade obtained through the hardening process gives the material a low toughness. Induction Hardening Applications The heat treating hardening process is utilized in various industries, including transportation, aerospace, and energy. Not only does eldec offer hardening systems, but they also offer a wide range of generators, tools and brazing and heating systems. 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. 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. 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. 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. Multi power: Plug-in expandable energy source for precise integration into systems (MF 5 – 30 kW). Rotation is essential for even and equal heat distribution on some components. 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 Annealing; Induction Bonding; Induction Brazing; Custom Applications; Induction Forging; Induction Hardening; Induction Heating; Induction Melting; Induction Preheating; Pipe and Tube; Products. Induction Hardening Equipment. 0 Home » Applications » Metal industry » Induction hardening. 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. Basic of Induction Heating; Advantages of Induction Heating; induction annealing process; Applications. 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. High productivity: Hardening quantity can be choosen according to your actual needs, segmentally and collectively in single and double station. With the precision frequency adjustment, even the most demanding jobs can be completed with ease. Our engineering expertise in developing induction hardening solutions has been applied by many automotive manufacturers worldwide. Treating the steel through tempering reduces the hardness in the material and increases its toughness. We also have metallurgical sectioning ability to test accurately hardened depths and extents. After quenching, the steel undergoes tempering, a low-temperature heat treatment process, to reach the desired hardness / toughness ratio. used in induction hardening are SAE 4140, 4150, 4340, 5150, 5140, and 52100. 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. 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. Hardening is usually increasing the hardness. Induction hardening can be used for a wide range of parts, and prom-inent examples are discussed in separate articles in this Volume. The current generated flows predominantly in the surface layer, the depth of this laye… Induction hardening is used to strengthen a specific area of a part. Hardening crankshafts involves consideration of 4 different heating zones - pins, journals, flanges, and shaft - with unique characteristics. Induction hardening and heat treating are ideal for a wide variety of applications in the transportation, aerospace, and energy industries, for processes such … 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. 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