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