Steel hardens. Gold melts. Copper pipes adhere to one another. That’s how induction heating works.
Because induction heating is a clean and non-contact process, manufacturers can use it in a vacuum or inert atmosphere. The core benefit is significantly greater energy and material efficiency and a higher degree of safety compared with other methods.
The concentrated, controlled heat of an induction heating manufacturing process is simple. With induction, the part to be heated is never directly exposed to flames or another heating element. This contactless process heats an electrically conductive metal and generates electric currents inside the metal using the principles of electromagnetic induction. Circulating eddy current flows against the electric resistivity of the metal part, producing accurate and localized heat without any direct contact between the part and inductor. The current flow combined with the resistance properties of a conducting part results in the heat production inside the part itself, with no thermal inertia, and without any loss in conduction. Induction is a perfect solution for this process, as induction makes it possible to have uniform and accurate heating.
The proper heating pattern is achieved by shaping a coil in a particular shape based on testing and the customer’s needs. As a result, heat is uniform from cycle to cycle and piece to piece. In addition, variations in input energy are compensated for automatically.
Several material properties influence induction heating performance, the two most crucial being electrical resistance and relative magnetic permeability. In addition, factors such as workpiece geometry and materials, the electrical frequencies used to heat, process temperatures, and manufacturing requirements all affect the process.
A well-designed induction heating process considers the heat-generating material’s properties, including its resistance, permeability (magnetic properties), part geometry, mass, and required heat-up rates. The characteristics of the induction device are then selected to meet heating requirements. In addition, operating frequency, rated capacity, powerhead configuration, energy density, and total efficiency is considered.