Technologies Archives - Page 31 of 36 - induction heating machine manufacturer

Induction Tempering Spring

Induction Tempering Spring with High Frequency Induction Heating Equipment

Objective Temper a spring by heating it to 300°C (570°F) in 2 – 4 seconds
Material Stainless steel AISI 302 springs- different length from 60 to
110 mm – outer diameters 8 mm.- wire diameter from 0.3 to 0.6 mm
Temperature 300°C (570°F)
Frequency 326 kHz
Equipment • DW-UHF-10kW induction heating system
• remote workhead, two 0.33μF capacitors (total 0.66μF)
• multi-turn C-channel coil developed for this application
Process Springs are mounted on non-metallic mandrels to facilitate loading and unloading and are placed inside the coil (picture). Power is applied for 2 – 4 seconds, completing the tempering process. The C-channel distributes the heating evenly and enables the convenient staging and removal of the springs.
Results/Benefits Efficiency: Energy is applied directly to the springs only;surrounding air and fixturing are not heated.
Precision: temperature and duration of process are controlled
Convenience: method integrates into a continuous process

Induction Hardening Inner

induction hardening inner coil surface treatment

Induction Heating Valve Head

Induction Heating Valve Head For Stress Testing With Induction Heating Equipment

Objective To heat the face of an engine valve head to 900°F and maintain the temperature for an extended time, high temperature stress test.
Material Engine valve head (two sizes), temperature sensing paint
Temperature 900 °F
Frequency200 kHz for large part; 271 kHz for smaller part
Equipment DW-UHF-10KW Induction Heating power supply, remote heat station with one 0.66 mF capacitor, a specially designed, multiturn induction coil and an optical pyrometer.
Process A specially designed multi-turn pancake coil was used to provide uniform heat to the part. To provide optimum coupling, the face of the valve head was placed approximately 3/8” away from the coil. RF induction power was applied for 4 minutes to heat the larger valve to 900°F; the smaller valve head required 2 minutes to reach the same temperature. For closed-loop temperature control, the optical pyrometer was then used to maintain the temperature at 900°F.
Results Uniform and repeatable results were obtained with the
DAWEI power supply and induction coil at 900°F. Depending on the part size, the correct temperature was reached in 2 to 4 minutes.

Induction Annealing Aluminum PIpe

Induction Annealing Aluminum PIpe With High Frequency Induction Heating Machine

Objective Annealing aluminum fuel tank fill neck to 650 ºF (343 ºC)
Material Aluminum fill neck 2.5” (63.5mm) diameter, 14” (35.5cm) long
Temperature 650 ºF (343 ºC)
Frequency 75 kHz
Equipment •DW-HF-45kW induction heating system, equipped with a remote workhead containing eight 1.0μF capacitors for a total of 2.0μF
• An induction heating coil designed and developed specifically for this application.
Process An eight turn helical is used to heat the tube for annealing. To anneal the full length of the tube, the tube is placed in the coil and heated for 30 seconds then rotated and the bottom half is heated for an additional 30. The tube is then bent while hot to prevent cracking.
Results/Benefits Induction heating provides:
• High efficiency, low energy cost
• Fast, controllable and repeatable process
• Prevention of cracks
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating

Induction annealing copper wires

Continuous Induction annealing copper wires with High frequency heating system

Objective Continuously anneal a copper wire used in electric motors at a rate of 16.4 yds (15m) per minute to eliminate work hardening caused during the drawing process.
Material Square copper wire 0.06” (1.7mm) dia., temperature indicating paint
Temperature 842 ºF (450 ºC)
Frequency 300 kHz
Equipment • DW-UHF-60kW induction heating system, equipped with a remote workhead containing eight 1.0μF capacitors for a total of 8.0μF
• An induction heating coil designed and developed specifically for this application.
Process A twelve turn helical coil is used. A ceramic tube is placed inside the coil to isolate the copper wire from the copper coil and to allow the copper wire to flow smoothly through the coil.
Power runs continuously to anneal at a rate of 16.4 yds (15m) per minute.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Flameless process
• Ideal for in-line production processes

Induction Annealing Aluminum

Induction Annealing Aluminum With High Frequency Heating System

Objective Annealing a 1” lip on aluminum cryogenic dewar that has been work hardened during the process of spin forming.
Material Aluminum dewar, lip has a 3.24” (82.3mm) ID and is 0.05” (1.3mm) thick
Temperature 800 ºF (427 ºC)
Frequency 300 kHz
Equipment •DW-UHF-10KW induction heating system, equipped with a remote workhead containing one 1.0 μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A two turn helical coil is used to heat the lip on the cryogenic dewar. The dewar is placed in the coil and power is applied for 2 minutes to anneal the required 1” heat zone.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Fast, controllable, accurate heating
• High efficiency, low energy cost
• Even distribution of heating

Induction Annealing Stainless Steel Tubes

Induction Annealing Stainless Steel Tubes With High Frequency Heating Equipment

Objective To anneal a ¼” area around an oval cutout on a stainless steel tube prior to extrusion
Material .75” (19mm), 1.5” (38.1mm) and 4” (101.6mm) diameter steel tubes
Temperature 1900 ºF ( 1038 ºC)
Frequency 300 kHz
Equipment • DW-UHF-20kW induction heating system, equipped with a remote workhead containing one 1.0μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A single turn helical coil is used on the 4” (101.6mm) diameter tubes and a two turn helical coil is used on the smaller diameters. The coil is placed over the oval cutout and power is
supplied for 15 seconds to anneal a .25 (6.35mm) diameter around the cutout.
Results/Benefits Induction heating provides:
• Precise and controllable placement of heat to anneal only the required area
• Faster process than flame
• Repeatable results
• Hands-free heating that involves no operator skill for manufacturing

Induction Annealing Steel Wire

Induction Annealing Steel Wire With High Frequency Heating System

Objective To heat 3” (76.2mm) from the end of the wire on a woven wire cloth 60” (1.52m) long. This prepares the wire mesh for bending in a press brake.
Material Woven wire cloth (steel) made of 1/2” (12.7) diameter wire, 60” (1.52m) long. Wires are 1.5” (38.1) apart
Temperature 1400 ºF (760 ºC)
Frequency 60 kHz
Equipment • DW-HF-60kW induction heating system, equipped with a remote workhead containing three 25μF capacitors for a total of 75μF
• An induction heating coil designed and developed specifically for this application.
Process A two turn oval coil is used to heat the woven wire. The woven wire is placed in the coil and heated for 50 seconds to soften a 60” (1.52m) length of the wire 3” (76.2mm) deep. The woven wire is then placed in a press brake for the bending process.
Results/Benefits Induction heating provides:
• Faster production process
• High efficiency, low energy costs compared to gas furnace
• Fast, controllable process
• Hands-free heating that involves no operator skill for manufacturing

Technology of Induction Forming Steel Plate

Technology of Induction Forming Steel Plate

Triangle heating technique using a gas flame is used to deform steel plate in ship construction. However, in the flame heating process, the heat source is often difficult to control and parts cannot be deformed efficiently. In this study, a numerical model is developed to study the triangle heating technique with the more controllable heat source of high frequency induction heating and to analyze the deformation of steel plate in the heating process. To simplify the many complex trajectories of the triangle heating technique, a rotational path of inductor is suggested and then a 2-dimensional circular heat input model is proposed. The heat flow and transverse shrinkage in steel plate during triangle heating with the induction heat are analyzed. The results of the analyses are compared with those of experiments to show the good
agreement. The heat source and thermo-mechanical analysis models proposed in this study were effective and efficient for simulating the triangle heating technique in the forming of steel plate in shipbuilding.

Technology of Induction Forming Steel Plate

Induction Brazing Steel Tips

Induction Brazing Steel Tips with Hihg Frequency Heating System

Objective To heat a steel tip and shank assembly to 1300°F (704°C) within 3 seconds for brazing with induction heating instead of torch brazing.
Material 0.1” (2.54mm) diameter steel tip & shank, 0.07” (1.78mm) diameter braze ring
Temperature 1300°F (704°C)
Frequency 800kHz
Equipment DW-UHF-4.5kW induction heating system, remote heat station containing one 1.2 microfarad capacitor.
Process A two turn helical coil is used to braze the dental parts. The braze ring is placed at the joint area of the steel tip and shank. Black flux is applied to the joint area. RF power is applied for 3 seconds to heat the parts to the established target temperature and the braze paste flows evenly and consistantly.
Results/Benefits Induction heating provides:
• Fast, accurate, repeatable heat
• Ability to heat very small areas within precise production tolerances
• Better joint quality, reduced oxidation
• Increased production rates and reduced labor costs