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Types of Induction Heating Application

Supertherm corporations deal in the manual, semi, or fully automated systems with standard machines for a wide variety of induction heating applications and custom engineered equipment to move parts seamlessly in your production environment. Manufacture of Induction Bar Heater and induction heating machines with industry expertise, process engineering, induction equipment, inductor design and development give their customers a reliable place to source the right machine.

Today we are discussing Hardening and Tempering with Induction.

Hardening is a process by which the hardness of a material is increased and ductility is decreased to strengthen high-wear surfaces and extend the service life of parts. The most suitable and often utilized method for hardening is Induction technology also known as Quenching and Tempering.

What is Quenching & Tempering?

A hardening process used by the Manufacture of Induction Melting Machine that can only be accomplished in medium to high carbon steel. The steel is heated to a high enough temperature for the crystal structure of the iron to transform from ferrite to austenite. In this altered crystal state, the steel can dissolve much more carbon than it otherwise could. The steel is then quenched using water, oil, or, in the case of induction tools, a water-polymer solution. This quenching cools the steel rapidly which stems carbon precipitates from forming which can reduce the final hardness of the steel. Once the steel cools to a low enough temperature, the crystal structure tries to return to its low-temperature state.

At this point, the steel has dissolved more carbon than it can hold in its original low-temperature state so it changes into a different crystal structure called martensite. Martensite is extremely hard due to having a distorted crystal structure and a higher saturation of carbon. At this point, the steel is very hard but as a result, it is also very brittle. Tempering involves heating the steel back up to a much lower temperature to slightly reduce the hardness and, in turn, reduce the brittleness. The temperature at which the steel is heated depends on how much hardness needs to be retained by the steel. Once the preferred hardness is achieved, the steel is quenched again to prevent residual heat from tempering the steel further.

Induction Case Hardening

Selective induction case hardening can improve the performance of parts by providing hybrid mechanical properties, hardness where needed on wear surfaces, and ductility in the core to provide impact resistance. This process is used by the mssssssssssss of Induction Billet Heater

Selective induction hardening can specifically target and apply heat rapidly to a localized area of a part. As a result, the part develops a layer, or case, of hardened material.

An ideal process for parts that are highly stressed in operation and require a combination of mechanical properties. For example, high yield strength, fatigue resistance, and resistance to wear at the same time.

The precise hardness pattern can be controlled by appropriate adjustment of the frequency used, induction coil geometry, power level, and the location of the part in the coil.

The hardness pattern remains highly consistent from part to part due to industry-leading precision Rotation during heating assures a uniform case.

Progressive Induction Hardening | Induction Scanning

Some parts require surface hardening in selected areas frequently to provide optimum performance and long service. Induction hardening, using progressive heating and quenching, provides a cost-effective way to process shafts or other parts.

By progressively passing a steel shaft through a heating coil into a water quench, the outer skin can be heated, quenched, and hardened without affecting its core.

Once a completely uniform case is required it is often necessary to rotate the shaft. The coil and the associate water quench usually form one unit, as the position of the water quench concerning the inductor is very important.

The water supply is often fed through the coil itself, as illustrated. Controlled scanning of shafts through the induction coil and quench ring while rotating produces controlled case depths over adjustable lengths of the shafts, all in on an automated cycle.

Control of the case depth depends upon the power input from the generator and the downward speed of the shaft through the induction coil while the length of the hardened section is controlled by a pyrometer which is set to suit specifications.

Once the desired case depth and hardness patterns are found by matching equipment parameters, these settings can be made consistent for a repeatable process across every part.

Though the application described above requires surface hardening, it is adaptable for other heat treating operations that require progressive heating, such as annealing and tempering. Supertherm Corporations are also manufacturers of Induction Annealing machines.

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Hardening & Tempering Induction Heating

Induction heating applications are of many types. Manufacture of Induction Melting Machine, Supertherm Corporations have all kinds of induction heating machines. The ability to heat any conductive material means that induction can be used for a wide range of processes.

We are discussing the first and foremost application here -Hardening and Tempering with Induction

Hardening can be defined as a process by which we can increase the hardness of a material and reduce its ductility. This is done to strengthen high-wear surfaces and extend the service life of parts. Different methods for hardening are available which can be used depending on the material being used. But Induction technology is often utilized in a hardening process and is known as Quenching and Tempering.

What is Quenching & Tempering?

It is a hardening process that can only be performed in medium to high carbon steel. 

The steel is heated to a high point temperature, just enough for the crystal structure of the iron to change from ferrite to austenite. 

In this altered crystal state, the steel can dissolve much more carbon than it otherwise could. 

The steel is then quenched using water, oil, or, in the case of induction equipment, a water-polymer solution. 

Quenching cools the steel rapidly which prevents the formation of carbon precipitates to reduce the final hardness of the steel. 

Once the steel cools to a low enough temperature, the crystal structure tries to return to its low-temperature state. 

By this time, the steel can dissolve more carbon than it can hold in its original low-temperature state 

This transforms into a different crystal structure called martensite. Martensite is extremely hard due to a distorted crystal structure and a higher saturation of carbon. 

Steel at this point, the steel becomes hard and very brittle. 

Tempering involves heating the steel back up to a much lower temperature to slightly reduce the hardness and, in turn, reduce the brittleness. Steel is heated to the desired temperature depending upon how much hardness needs to be retained by the steel. 

Once the desired hardness is achieved, the steel is quenched again to prevent residual heat from tempering the steel further.

Quenching & Tempering with Induction has the most distinct advantages. This procedure requires extreme amounts of precision in both the heating and quenching of the steel to achieve the desired hardness profile. Small variations matter a lot in this process such as heating for a second too long or quenching at the wrong temperature can result in large variations from part to part. Precise control of the process becomes paramount and therefore Induction technology offers more control than any other method of heating. Manufacture of Induction Bar Heater with expertise in induction that can be applied to custom applications, ranging from billet heating to susceptor heating and more.

Manufacture of Induction Annealing Machine and induction heating use automatic handling and fixturing components for heating and quenching to provide high production rates and help to produce consistent results part after part. Induction is by far the fastest method of hardening and heat treating proving it to be the perfect solution for any facility looking to step up production to the next level.

The induction heating process results in minimal distortion, no surface decarburization, fine grain microstructure, and precisely controlled hardness patterns.

Supertherm Corporations are the well-known leaders in thermal processing and induction heating machines.No matter what you need to melt, heat treat, forge, roll, cut or weld, you can do it better with the advanced technologies and equipment produced by the Manufacture of Induction Tube Welder and other induction heating machines.