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 forging uses induction to heat metal parts before they are shaped, or ‘deformed’ by presses or hammers.
What are the benefits?
Induction forging has several key advantages over furnace forging. The speed and controllability of induction ensures high throughput. Induction also minimizes oxidation and helps maintain metallurgical integrity. And since induction delivers precise, localized heat, it saves energy. The consistency and repeatability of induction make it ideal for integrating into automated production lines.
Where is it used?
Induction forging is widely used in the metal and foundry industries to heat billets, bars and bar ends. Metals commonly forged with DaWei Induction Heating systems include aluminum, brass, copper, steel and stainless steel.
What equipment is available?
Three families of DaWei Induction heating equipment can be used for forging applications: DW-MF series, KGPS series. However, DW-MF induction forging furnace includes various models that are specially designed for high-output forging of billets, bars, handlebars, bar ends, bolts and pre-formed components.
Induction melting is a process where metal is melted into liquid form in an induction furnace’s crucible. The molten metal is then poured from the crucible, usually into a cast.
What are the benefits?
Induction melting is extremely fast, clean and uniform. When correctly performed, induction melting is so clean that it is possible to skip the purification stage necessary with other methods. The uniform heat induced in the metal also contributes to a high-quality end result. DaWei Induction melting furnace have advanced ergonomic features. They not only make workplaces safer, they increase productivity by making the melting process faster and more comfortable. Where is it used? DaWei Induction melting systems are used in foundries, universities, laboratories and research centers. The systems melt everything from ferrous and non-ferrous metals to nuclear material and medical/dental alloys.
What equipment/furnace is available?
DaWei Induction Heating Machine Co offers many different induction furnace ranges to suit a wide variety of melting needs: single-axis tiltpour, dual-axis tilt-pour, moving coil, rollover and laboratory.
Induction Brazing is a materials-joining process that uses a filler metal (and usually an anti-oxidizing solvent called flux) to join two pieces of close-fitting metal together without melting the base materials. Instead, induced heat melts the filler, which is then drawn into the base materials by capillary action.
What are the benefits?
Induction brazing can join a wide range of metals, even ferrous to non-ferrous. Induction brazing is precise and quick. Only narrowly defined areas are heated, leaving adjacent areas and materials unaffected. Correctly brazed joints are strong, leak-proof and corrosion resistant. They are also very neat, usually requiring no further milling, grinding or finishing. Induction brazing is ideal for integrating into production lines.
Where is it used?
DaWei Induction brazing systems can be used for virtually any brazing task. To date, our systems are typically used in the electrotechnical industry to braze generator and transfomer components like bars, strands, rings, wires and SC-rings. They also braze fuel pipes and AC and brake parts for the automotive industry. The aeronautics sector uses induction to braze fan blades, blades for casings, and fuel and hydraulic systems. In the houseware industry our systems braze compressor components, heating elements and faucets. What equipment is available? Our Induction brazing solutions usually include an DaWei Handheld Induction heating system.
Induction hardeninguses induced heat and rapid cooling (quenching) to increase the hardness and durability of steel.Induction heating is a no-contact process that quickly produces intense, localized and controllable heat. With induction, only the part to be hardened is heated. Optimizing process parameters such as heating cycles, frequencies and coil and quench design results in the best possible outcomes.
What are the benefits?
Induction hardeningboosts throughput. It is an extremely fast and repeatable process that integrates easily into production lines. With induction it is usual to treat individual workpieces. This ensures each separate workpiece is hardened to its own precise specifications. The optimized process parameters for each workpiece can be stored on your servers. Induction hardening is clean, safe and typically has a small footprint. And because only the part of the component to be hardened is heated, it is extremely energy-efficient.
Where is it used?
Induction heatingis used to harden numerous components. Here are just a few of them: gears, crankshafts, camshafts, drive shafts, output shafts, torsion bars, rocker arms, CV joints, tulips, valves, rock drills, slewing rings, inner and outer races.
Induction Heatingis a flame-free, no-contact heating method that can turn a precisely defined section of a metal bar cherry red in seconds.How is this possible?
How Induction Heating works?
Alternating current flowing through an induction coil generates a magnetic field. The strength of the field varies in relation to the strength of the current passing through the coil. The field is concentrated in the area enclosed by the coil; while its magnitude depends on the strength of the current and the number of turns in the coil. (Fig. 1) Eddy currents are induced in any electrically conductive object—a metal bar, for example—placed inside the induction coil. The phenomenon of resistance generates heat in the area where the eddy currents are flowing. Increasing the strength of the magnetic field increases the heating effect. However, the total heating effect is also influenced by the magnetic properties of the object and the distance between it and the coil. (Fig. 2) The eddy currents create their own magnetic field that opposes the original field produced by the coil. This opposition prevents the original field from immediately penetrating to the center of the object enclosed by the coil. The eddy currents are most active close to the surface of the object being heated, but weaken considerably in strength towards the center. (Fig. 3) The distance from the surface of the heated object to the depth where current density drops to 37% is the penetration depth. This depth increases in correlation to decreases in frequency. It is therefore essential to select the correct frequency in order to achieve the desired penetration depth.
what is advantages of induction heating,brazing,hardening,melting and forging,etc?
Why choose induction heatingover open flame,convection,radiant or another heating method?Here’s a short summary of the major advantages that modern solid state induction heating offers for lean manufacturing:
Induction heatingis 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. 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.
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, advancedinduction heating systemshave 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.
Induction heating systemsdo 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.
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.
Induction heating is the process of heating an electrically conducting object (usually a metal) by electromagnetic induction, where eddy currents (also called Foucault currents) are generated within the metal and resistance leads to Joule heating of the metal.Induction heating is a form of non-contact heating,when alternating current flows in the induced coil, varying electromagnetic field is set up around the coil, circulating current(induced, current, eddy current) is generated in the workpiece(conductive material), heat is produced as the eddy current flows against the resitivity of the material.The basic principles of induction heating have been understood and applied to manufacturing since the 1920s. During World War II, the technology developed rapidly to meet urgent wartime requirements for a fast, reliable process to harden metal engine parts. More recently, the focus on lean manufacturing techniques and emphasis on improved quality control have led to a rediscovery of induction technology, along with the development of precisely controlled, all solid state induction power supplies.
How Induction Heating Work?
An induction heater (for any process) consists of an induction coil (or electromagnet), through which a high-frequency alternating current (AC) is passed. Heat may also be generated by magnetic hysteresis losses in materials that have significant relative permeability. The frequency of AC used depends on the object size, material type, coupling (between the work coil and the object to be heated) and the penetration depth.High Frequency Induction heating is a process which is used to bond, harden or soften metals or other conductive materials. For many modern manufacturing processes, induction heating offers an attractive combination of speed, consistency and control.
What’s Induction Heating Applications
Induction heating is a rapid ,clean, non-polluting heating form which can be used to heat metals or change the conductive material’s properties. The coil itself does not get hot and the heating effect is under controlled. The solid state transistor technology has made induction heating much easier,cost-effective heating for applications including soldering andinduction brazing ,induction heat treating, induction melting,induction forging etc.