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Induction Heat Treatment Process

With 6 induction heat treating machines, we soften or harden metal through targeted heating, hardening, tempering, or annealing. We specialize in induction heat treating a range of metal parts, such as drive shafts, bearings, axel shafts, camshafts, and sprockets.

Induction Annealing for Metals

Our induction heat treatment process is best suited for enhancing the ductility of steel, stainless steel, and carbon steel parts without compromising on the dimensional stability of the materials. In addition, our induction heating process is environmentally friendly and offers higher heating intensity compared to conventional metal treatment techniques.

Induction Hardening Capabilities

Factors such as electrical properties of pieces, the coupling efficiency of coils, and the degree of temperature change required are taken into consideration during induction heat treatment. Our Zion Z scan induction heat treated features a 6 position rotary index table and easy-to-maintain hydraulics. The Zion Z scan induction heat treated is capable of heat treating pieces with diameters up to 1 1/4" and lengths up to 20".

Tempering Services

Provide your design specifications for your piece part and allow us to generate a quote.

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Air & Fuel Oil Coolers - Turbine Lubrication System Components

Air Oil Coolers

Two basic types of oil coolers in general use are the air-cooled and the fuel-cooled. Air oil coolers are used in the lubricating systems of some turbine engines to reduce the temperature of the oil to a degree suitable for recirculation through the system. The air-cooled oil cooler is normally installed at the forward end of the engine. It is similar in construction and operation to the air-cooled cooler used on reciprocating engines. An air oil cooler is usually included in a dry-sump oil system. [Figure 1] This cooler may be air-cooled or fuel-cooled and many engines use both. Dry- sump lubrication systems require coolers for several reasons. First, air cooling of bearings by using compressor bleed-air is not sufficient to cool the turbine bearing cavities because of the heat present in area of the turbine bearings. Second, the large turbofan engines normally require a greater number of bearings, which means that more heat is transferred to the oil. Consequently, the oil coolers are the only means of dissipating the oil heat.

Fuel Oil Coolers            

The fuel-cooled oil cooler acts as a fuel oil heat exchanger in that the fuel cools the hot oil and the oil heats the fuel for combustion. [Figure 2] Fuel flowing to the engine must pass through the heat exchanger; however, there is a thermostatic valve that controls the oil flow, and the oil may bypass the cooler if no cooling is needed. The fuel/oil heat exchanger consists of a series of joined tubes with an inlet and outlet port. The oil enters the inlet port, moves around the fuel tubes, and goes out the oil outlet port.

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Effect of cryogenic treatment on case-hardening steels

Process alternatives to optimize their final properties

��In the field of Induction Hardening in Faridabad, it is usually considered that cryogenic temperatures are those below 120 K (-153°C). Consequently, conventional subzero treatments, often referred to as shallow cryogenic treatments and usually performed at temperatures around -80°C, cannot be regarded as real cryogenic processes.

Cryogenic temperatures couldn’t be achieved until the late 19th century and, therefore, the emergence of cryogenic treatments in industry is relatively recent. The development of this technology has been based mainly on empirical results. The basic research of the transformations produced in the materials when exposed to cryogenic temperatures is usually conducted with significant delay with regard to development of practical applications.

In general, cryogenic treatments have been considered as separate operations, added to the conventional heat treatments. This is something that has conditioned the development of knowledge in this field, and also the reliability of the results obtained with these processes. Maybe this happens because, very often, this technology is used in tools and finished components, without paying much attention to the previous operations. This approach doesn’t enable a good control over the process results since these depend on the material history before the cryogenic treatment. And, obviously, the previous heat treatments play a crucial role.

In this regard, the consideration of cryogenic treatments as independent operations is a mistake. The right way to contemplate them is not as a supplementary step, but as an integral part of the overall heat treatment process. Only in this way its full potential will be exploited, selecting the route that is most adequate in each Case Hardening in Faridabad depending on the material considered and the application in which it will be used.

We will try to illustrate it with an example. Let’s consider a case hardening steel like 18NiCrMo5, which is commonly used in applications where high yield strength and good wear resistance are required (shafts, gears, cams, etc.). The heat treatment process of this steel starts with a cementation step in order to increase the carbon content in the surface of the component. The subsequent quenching, followed by a tempering cycle at not more than 200°C, provides a very hard surface while the core remains soft and tough.

When considering the cryogenic treatment of a component made of case hardened steel, two basic strategies could arise. One is to apply it to the already heat treated part, that is, after tempering. The other one is to perform the cryogenic process after quenching but before tempering.

Several investigations focused on studying the effects of cryogenic treatments in this steel grade have been carried out in recent years, but the results seem confusing and sometimes even contradictory. Actually, this happens because in most of these studies only one of the two approaches has been considered, not taking into account that the results that are obtained with each of the treatment strategies are significantly different.

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Induction Heat Treatment Process

With 6 induction heat treating machines, we soften or harden metal through targeted heating, hardening, tempering, or annealing. We specialize in induction heat treating a range of metal parts, such as drive shafts, bearings, axel shafts, camshafts, and sprockets.

Induction Annealing for Metals

Our induction heat treatment process is best suited for enhancing the ductility of steel, stainless steel, and carbon steel parts without compromising on the dimensional stability of the materials. In addition, our induction heating process is environmentally friendly and offers higher heating intensity compared to conventional metal treatment techniques.

Induction Hardening Capabilities

Factors such as electrical properties of pieces, the coupling efficiency of coils, and the degree of temperature change required are taken into consideration during induction heat treatment. Our Zion Z scan induction heat treater features a 6 position rotary index table and easy-to-maintain hydraulics. The Zion Z scan induction heat treater is capable of heat treating pieces with diameters up to 1 1/4" and lengths up to 20".

Tempering Services

Provide your design specifications for your piece part and allow us to generate a quote. Start this induction heat treating process by selecting the "Request information" button.

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What's the difference between single shot hardening and traverse hardening?

There are two methods of heating when using induction: eddy current heating and hysteretic heating. When it comes to hardening, however, the two main types are known as single shot hardening and traverse Induction Hardening in Faridabad. Single shot hardening systems employ the use of rotated components in the induction coil, and the entire area is heated at the same time for a pre-determined amount of time using either a drop quench system or a flood quench system. Single shot hardening is typically used in applications in which no other method will reach the intended result, for example, hardening the flat face of hammers and producing small gears.

Traverse hardening, on the other hand, uses an induction coil for the workpiece to pass through progressively. A following quench spray or ring is used, This process is often used in the manufacturing of shaft type components, including axle shafts, steering components, drive shafts, excavator bucket pins, and power tool shafts. The workpiece is passed through a ring type inductor, which usually features a single turn.

Traverse hardening applications are also used in the manufacturing of certain edge components, including paper knives, lawnmower bottom blades, hacksaw blades, and leather knives.

Ultimately, understanding the processes and details of various induction hardening methods is the key to determining which heat treatment type is best suited for your application needs. For more information about induction heating accessories and other induction equipment for sale, contact Inductwell pvt Ltd

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Advantages, Disadvantages of Induction Heat Treatment

The process works on the simple principle that when an electrical current is passed through a conductor, an electro-magnetic field is created around the conductor. The conductor is generally (not in all cases) a coiled copper conductor through which a high-frequency magnetic field is induced to flow through the coil. This sets up a magnetic field around the coil and within the coil. If a steel bar is inserted into the coil, the magnetic flux that is generated will create eddy currents within the surface of the steel bar, which creates heat within the immediate surface of the inserted bar within the conductance coil.

The depth of the heated and hardened surface will be dependent on the carbon content of the steel bar, induction frequency, induction power, residence time within the coil and quench medium.

The steels that can be used for an induction heat-treatment procedure will generally contain approximately 0.3-0.5% carbon. Care needs to be taken with the higher carbon grades for the potential risk of cracking. Chromium can be added to the steel (generally 0.25-0.35%) to interact with the carbon content of the steel and produce surface chromium carbides of Induction Hardening in Faridabad.

It is at this point that the decision should be made if the system will quench with water or a poly-alkaline glycol mixture to reduce the risk of cracking. The Induction Hardening Job Work coil can be designed to accommodate any geometric shape that will allow access to the contour to be heat treated and quenched accordingly.

The following will show some of the advantages and disadvantages of induction heat treatment.

Advantages

•             Localized areas can be heat treated

•             Very short surface heat-up times

•             Steel can be pre-heat treated to obtain prior core hardness values

•             Very minimal surface decarburization

•             Very minimal surface oxidation

•             Slight deformation (bending); this can occur due to internal residual machining stresses

•             Straightening can be carried out on a deformed bar/shaft; however, care must be exercised

•             Increased fatigue strength

•             Can be incorporated into cell manufacture

•             Low operating costs

Disadvantages

•             High capital investment (however, the investment will be dependent on the degree of automation built into the equipment)

•             Only certain steels can be induction hardened

•             The method is restricted to components having a shape that is suitable for Induction Hardening.

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Induction Hardening – Process, History and Advantages

Induction Hardening is a type of heat treatment in which metal parts are heated by electromagnetic induction and then quenched. It is also a type of case hardening and can be used for many steel and steel alloys to improve surface layer properties such as fatigue resistance and hardness.

Induction Hardening Process

Induction Hardening can be split into two steps. The first one is induction heating, in which electrically conducting metals are heated with an electromagnet. The quenching phase follows directly after to alter the surface structure of the material.

Induction Heating

Materials such as steel are typically placed inside a water cooled copper coil where they are subject to an alternating magnetic field. They undergo electromagnetic induction by means of an electromagnet and an electronic oscillator. This oscillator sends alternating currents through the electromagnet, causing alternating magnetic fields that penetrate the material. The results are eddy currents (loops of electrical current) which heat the object within the coil. Induction hardening is a form of surface hardening in which the depth can be up to 8mm. The deeper the currents penetrate, the higher the frequency of the alternating magnetic fields have to be Case Hardening in Faridabad.

Steels that have a ferromagnetic structure (which is inherited from the iron) can also be heated by magnetic hysteresis losses. Magnetic hysteresis losses produce heat by re-aligning magnetic domains, although it depends on the frequency of the currents, the penetration depth and the properties of the material (size, density, alloys) how much heat can be generated.

Quenching

Directly after the induction heating process, the object has to be quenched, meaning that it has the be cooled down extremely quickly. To do that, the workpiece is typically placed in a tank of oil or water, although sometimes cold air is used. Quenching ensures that only the surface is hardened and that heat doesn’t spread into the core of the material, avoiding phase transformations from arising. Furthermore, the rapid cooling down creates a martensitic or ferritic-martensitic structure on the surface layer. These structure display higher tensile strength and low initial yielding stress than a purely ferritic structure.

History

Induction heating was first developed and introduced in its earliest form in 1831 by Michael Faraday. He could prove that an electromotive force could be created by winding two copper coils around a magnetic core while turning one of the windings on and off which affected the other one. These currents were created by alternating magnetic fields around the magnetic core. Because neither of the coils touch, the electromotive force is induced into the second coil, the process was called induction heating.

Properties that improve due to induction hardening

Deeper Case Depth: Induction hardening can penetrate the surface of up to 0.31 inches (8 mm). This depends on the process of induction hardening and the material’s properties.

Finer Grain Size: As mentioned above, induction hardening changes the grain size on the surface of materials. A finer grain size increases hardness because the surface is harder to penetrate.

Higher wear and fatigue resistance: Induction hardening improves wear resistance because the structure of the surface layer is altered. Ferritic steels obtain a martensitic structure which provides improved wear resistance.

Induction hardening in Faridabad is a good alternative to boronizing, which is a type of surface hardening BorTec specializes in. Induction hardening is recommended when only hardness should be improved. If you’re looking for a treatment that can also improve adhesion, resistance against abrasive wear, good stability at high temperatures and resistance against acids, the certified BoroCoat treatment is the better choice. However, it depends on the area of application and other factors which hardening technique is more suitable for your needs.

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Total vs. Effective Case Depth

One of the benefits of induction hardening is the ability to selectively apply a surface hardness or case hardness to steel materials. The case hardness will allow the piece to have superior wear and strength characteristics at the surface, but allow the interior of the piece to remain flexible in Induction Hardening in Faridabad.

Case hardness is defined as the outer surface that has been made harder than the interior, or core. The term case depth refers to the depth of the case, or hardened layer of a piece of material. Case depth is typically measured as “total” or “effective”. The two terms are sometimes misunderstood, but are different and it is important to understand those differences.

The term total Case Hardening in Faridabad refers to the depth of hardness where the hardened layer reaches the same hardness and properties as the base or core material. Total case depth is typically measured by sectioning the work piece and polishing and etching with an acid solution to reveal the depth of the hardened layer. The measurements can then be taken visually and measured using a calibrated eyepiece or scale to qualify the total depth.

The term effective case depth refers to the depth where a hardness measurement drops below a specified point. The hardness will then continue to decline until the “total” case depth is reached. The hardness at the effective depth is specified based on the characteristics required and the hardenabiltiy of the material. For example, high carbon steel that may have a minimum surface hardness of 60 HRc may call for an effective case depth of 0.120” at 50 HRc. The method of determining effective case depth involves sectioning the piece and polishing the surface. Measurements of the hardness are then taken at regular depth intervals until the hardness drops to the specified range. This distance from the surface is then measured to determine the effective depth in

Induction Hardening

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Heat and surface treatment

Rolling bearing rings and rolling elements must:

•             be hard enough to cope with fatigue and plastic deformations

•             be tough enough to cope with applied loads

•             be sufficiently stable to experience only limited changes of dimensions over time

The required properties are achieved by heat and surface treatments of Induction Hardening in Faridabad.

Hardening

There are three typical hardening methods that may be applied to bearing components:

•             Through-hardening

This is the standard method for most bearings and provides good fatigue and wear resistance, as hardening is applied over the full cross section.

•             Induction-hardening

Surface induction-hardening is used to selectively harden a component’s raceway to limit rolling contact fatigue, leaving the remainder of the component unaffected to maintain structural strength.

•             Case-hardening

Case Hardening in Faridabad provides hardness to the surface. It is used, for example, where bearing rings are subjected to high shock loads causing structural deformations.

Dimensional stability

Heat treatment is used to limit dimensional changes due to metallurgical effects at extreme temperatures. There is a standardized classification system for dimensional stability. The various SKF bearing types are stabilized to different classes as standard.

Surface treatment and coatings

Coating is a well-established method for providing bearings with additional functional benefits to accommodate specific application conditions. Widely used coatings are zinc chromate and black oxide.

Two other methods developed by SKF have proven successful in many applications:

•             INSOCOAT bearings are standard bearings that have the external surfaces of their inner or outer ring coated with an aluminium oxide layer. This coating increases resistance to electric current through the bearing.

•             NoWear enhances wear-resistance of the raceway or rolling element surfaces. It can help the bearing withstand long periods of operation under poor lubrication conditions and to reduce the risk for low load damages Induction Hardening.

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How Does Hardening and Tempering Improve the Strength of Materials?

Material strength isn’t a straightforward property, not when we’re talking about structurally-capable alloys. Yes, a hardened work piece is stiff, but it could also be brittle. In reality, strength is an amalgamated property, something that combines hardness and material tempering. In using metal solidification technology as our starting point, we’ll explain the importance of hardening, then we’ll introduce tempering, a process that counters the hardening work by adding ductility to the alloy amalgamation regime of Induction Hardening in Faridabad.

Determining Central Precepts

The purpose of the hardening stage is to ensure it won’t deform, no matter how heavy the applied load. If that load compresses the metal part won’t collapse in upon it, won’t fracture, nor warp. Instead, it stands resolute, with its original shape locked in place. In essence, the mechanical backbone of the processed metal is stiffened. But wait, a structure that’s imbued with this lone property could crack and crumble, unless there’s a ductility feature in place, that is. Workpiece tempering assumes this role, for this important low-temperature work phase is purpose-built as a material brittleness alleviator.

Heat Treatment Balancing and Counterbalancing

If a super-heated environment raises the transformative temperature of a selected alloy past its specified critical transformation threshold then is cooled rapidly, the workpiece hardens. Technically speaking, all pearlite content has been converted into martensite, an allotrope whose needle-like microcrystalline structure is extremely hard. The problem here is the brittleness of the martensite, an issue that can introduce stress and material deformation, although these effects are mitigated somewhat by the length of time the part was held at its transformative temperature. Tempering is required to counteract the strengthening (hardening) phase, a stage that can add material weakness (brittleness). The work piece has been hardened and rapidly cooled, via a quenching station, so now the tempering process enters the heat treatment line as a counterbalance. Again, heat is the brittleness mitigating agent, but this is a reduced thermal load, a heat source that increases material strength by adhering to a low temperature. Intelligently managed in this manner, the tempering temperature reduces alloy brittleness while augmenting the work piece’s strength and overall ductility of Case Hardening in Faridabad.

We’ve described quite a few hardening and tempering methods over the months. They create tough metal parts and superior finishes, parts that are as material strong as they are corrosion-resistant. Still, what we’re stressing today is an overall strategy, a meeting of different heat treatment principles and processes. Designed to produce a desired hardness-to-strength ration, the hardening and tempering equipment use time and fiery temperatures to imbue a chosen part with a requisite material strength rating in Induction Hardening.

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Difference between - Induction Hardening & Induction Flame Hardening

Induction Hardening

Induction hardening is a process used for the surface hardening of steel and other alloy components. The parts to be heat treated is placed inside water cooled copper coil and then heated above their transformation temperature by applying an alternating current to the coil. The alternating current in the coil induces an alternating magnetic field within the work piece, which if made from steel, caused the outer surface of the part to heat to a temperature above the transformation range. Parts are held at that temperature until the appropriate depth of hardening has been achieved, and then quenched in oil, or another media, depending upon the steel type and hardness desired. The core of the component remains unaffected by the treatment and its physical properties are those of the bar from which it was machined or preheat treated. The hardness of the case can be HRC 37 - 58. Carbon and alloy steels with carbon content in the range 0.40 - 0.45% are most suitable for this process. In some cases, parts made from alloy steels such as 4320, 8620 or 9310, like steel and paper mill rolls, are first carburized to a required case depth and slow cooled, and then induction hardened. This is to realize the benefit of relatively high core mechanical properties, and surface hardness greater than HRC 60, which provides excellent protection.

While Induction Hardening is most commonly used for steel parts, other alloys such as copper alloys, which is solution treated and tempered, may be induction hardened as well. Applications include hardening bearing races, gears, pinion shafts, crane (and other) wheels and treads, and threaded pipe used for oil patch drilling.

Induction Flame Hardening

Flame hardening is similar to induction hardening, in that it is a surface hardening process. Heat is applied to the part being hardened, using an oxy- acetylene (or similar gas) flame on the surface of the steel being hardened and heating the surface above the upper critical temperature before quenching the steel in a spray of water. The result is a hard surface layer ranging from 0.050" to 0.250" deep. As with induction hardening, the steel component must have sufficient carbon (greater than 0.35%). The composition of the steel is not changed; therefore core mechanical properties are unaffected. Flame hardening produces results similar to conventional hardening processes but with less hardness penetration. Applications for flame hardening are similar to those for Induction Hardening in Faridabad, although an advantage of flame hardening is the ability to harden flat surfaces. Flat wear plates and knives can be selectively hardened using this process.

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BASIC FUNCTIONS OF A LUBRICANT

In order to lubricate successfully, a basic understanding of a lubricant’s function is necessary. A lubricant, whether it is oil or grease, can at any time perform up to six basic functions simultaneously.

These functions are to:

• Reduce friction

• Reduce wear

• Absorb shock

• Reduce temperature*

• Minimize corrosion

*REDUCE TEMPERATURE

A major benefit of reduced friction is reduction in operating temperature. Caution must be observed in the overall assessment here. Because excessive lubricant may cause fluid friction, which may in turn raise the temperature of Induction Hardening in Faridabad.

Assuming that the correct quantities of lubricant are used, lubricants can be an excellent dissipater of heat, especially in re-circulative oil (or splash oil) systems where the Oil Coolers in Faridabad is passed over the moving part – where it not only lubricates, but also absorbs the heat and returns to the reservoir where it cools before recommencing the cycle. (Sometimes it is necessary to pump the lubricant through oil cooler, which will allow for a smaller reservoir.)

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What is the technological difference between Case Hardening and Induction Hardening?

Two methods have become established for Induction hardening work pieces in mass production: case hardening and induction hardening. A comparison of these two methods shows their differences and the advantages of each.

Case Hardening vs. Induction Hardening – a Comparison

If one compares the two methods for hardening steel work pieces (for a general explanation of hardening see here: Hardening), then the first striking difference is the parts handling. While case hardening processes a large number of work pieces at the same time, induction hardening focuses on the individual work piece. With induction hardening, components are hardened work piece by work piece. For case hardening, “batch by batch” would be a better description.

Of courses, this has an impact on the manufacturing. While case hardening relies on parts logistics to carry parts between the production line and hardening, induction hardening can be integrated directly in the production line with a suitable hardening machine (e.g. MIND series) and be part of the cycle.

Case hardening in detail

As mentioned above, case hardening is done in batches. As with induction hardening, the goal is to harden the outer layer of work pieces. 

In case hardening the work pieces are hardened by carburization. The steel is heated to over 880 °C to become austenitic. Then coal is transferred into the part from a CO-emitting medium through the part’s surface. The diffusion causes the edge of the work piece to receive more carbon, while the carbon density remains the same toward the center. 

Hardening occurs after the application of carbon. Penetration of carbon is critical for the hardness and the depth hardness characteristic of the work piece. The hardening, i.e. the hardness and the hardening depth, is defined by the carbonization depth, the receptiveness and thus the harden ability of the steel, and the quenching. The more carbon is inside an area of the work piece, the more successful the hardening in that area. 

After hardening, the work pieces are annealed (for more information about annealing please see here: Annealing) to restore some of their plasticity. The goal of any hardening process is to make the edge resistant to mechanical loads while giving the part enough elasticity to deflect external forces without damage. 

There are two ways to influence the hardening depth in case hardening: One is to manipulate the heating of the work piece, e.g. by application of special pastes that prevent heating in certain places. The other is by influencing the quenching process, e.g. by immersing only certain parts of the work piece.  

With both methods, results are not particularly accurate and reproducible only within a relatively wide tolerance range. This is very different for Air Coolers and Oil Coolers in Faridabad.

Induction hardening in detail

As mentioned above, each part is hardened separately with the induction hardening technology. Each part is heat treated, quenched, and annealed (if necessary) separately.

In addition to integration in the production line, the great advantages of induction hardening are precise control and reproducibility of hardening results. 

To achieve this, the entire hardening process from the inductor and the applied energy and frequency to quenching and annealing is specially adapted to the relevant work piece. This yields excellent hardening results, even for work pieces with complex geometriesening

Which hardening method is the right one?

Which Induction hardening in Faridabad process is suitable for an application depends on several factors. Both methods, case hardening and induction hardening, have advantages and downsides.

For the mass production of components in medium or large quantities however, induction hardening offers a range of benefits:

1.       With a suitable hardening machine, induction hardening can be fully integrated in the cycle of the production line and automated.

2.       Especially with induction hardening, results are reproducible, which contributes to a consistently high quality in production.

3.       This reduces unit costs considerably

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Air & Fuel Oil Coolers - Turbine Lubrication System Components

Air Oil Coolers

Two basic types of oil coolers in general use are the air-cooled and the fuel-cooled. Air coolers oil coolers are used in the lubricating systems of some turbine engines to reduce the temperature of the oil to a degree suitable for recirculation through the system. The air-cooled oil cooler is normally installed at the forward end of the engine. It is similar in construction and operation to the air-cooled cooler used on reciprocating engines. An air oil cooler is usually included in a dry-sump oil system. [Figure 1] This cooler may be air-cooled or fuel-cooled and many engines use both. Dry- sump lubrication systems require coolers for several reasons. First, air cooling of bearings by using compressor bleed-air is not sufficient to cool the turbine bearing cavities because of the heat present in area of the turbine bearings. Second, the large turbofan engines normally require a greater number of bearings, which means that more heat is transferred to the oil. Consequently, the oil coolers are the only means of dissipating the oil heat.

Fuel Oil Coolers

The fuel-cooled oil cooler acts as a fuel oil heat exchanger in that the fuel cools the hot oil and the oil heats the fuel for combustion. Fuel flowing to the engine must pass through the heat exchanger; however, there is a thermostatic valve that controls the oil flow, and the oil may bypass the cooler if no cooling is needed. The fuel/oil heat exchanger consists of a series of joined tubes with an inlet and outlet port. The oil enters the inlet port, moves around the fuel tubes, and goes out the oil outlet port and Induction Hardening Faridabad.