How Induction Annealing Works
Our induction annealing systems heat very small areas within precise production tolerances without disturbing individual metallurgical characteristics, annealing materials quickly and precisely.
How Induction Annealing Works
Our induction annealing systems are capable of heating very small areas within precise production tolerances, without disturbing individual metallurgical characteristics, annealing materials quickly and precisely.
Induction annealing Application Notes
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Clients are looking to upgrade cutting-tool torch brazing process with a fast, controllable and repeatable process.
A custom-designed single position multiple-turn helical coil was built to generate the required heating for this annealing application. Initial tests were conducted to optimize the power delivered to the part.
To anneal electrical crimp contacts of different dimensions. The client took advantage of THE LAB’s expertise to prove out their process in a way that met their time, quality and budgetary requirements.
The client is building a system with induction. Induction achieved the client’s speed requirements and induction’s modest footprint works well within the system.With induction you can expect the same result every time.
It took 45 seconds to heat the tube to the target temperature for this annealing application, which met the client's objective
Induction offers the same result every time, which makes it ideal for a high volume process such as this one. The previous oxidation issue forced them to polish the handles which added a step in their manufacturing process.
The client wants to anneal a stainless steel tube while avoiding oxidation. Induction offers the same result every time, copper tubes of various geometries heated to temperature in a matter of seconds, which makes it ideal for a high volume process such as this one.
The ammunition industry has been annealing with inefficient methods which require much floor space, lack consistency, create excess inventory carry costs, and don't permit in-process inspections. Induction heating ensures each and every case is quality annealed, reducing variation and damage typically found in mass annealing processes.
The client's parts were heated to the desired temperature in less than three seconds. Their previously-used gas oven required twice as much heating time as the induction heating process. Induction heating is more energy-efficient and requires less space compared to a gas oven.
Looking to replace an inefficient oven process, a stainless steel tube is heated in just 30 seconds, improving efficiency for this application. A custom-designed single position multi-turn helical coil was built to generate the required heating for this application
The client wanted to be able to heat parts of various sizes, which was achieved with a concentrator coil. This is a new process for the client, and Ambrell's lab expertise proved very valuable when creating the process...
Induction annealing achieved the targeted steel wire temperature within three seconds. Ambrell performed a free laboratory test, designed a cost efficient, in-house process and connected them with an automation partner to maximize productivity. The client now has better control over their end product.
Our client had a requirement to anneal large quantities of work-hardened stainless steel crowns. Induction was suggested for its precise, controllable heating. Since oxidation is unacceptable in the finished dental product, induction heating is the appropriate choice for heating in an inert atmosphere.
To anneal brass tubes into handrails, a twelve-turn helical coil was used to heat an 8”x3” (20.3cm x 7.6cm) area above the end of the tubes. Each of the four tubes require a different heat cycle and time to reach the required temperature.
A fourteen-turn coil is used to heat 3.9” (100mm) of zinc wire for this zinc wire application. The wire is placed in the coil for 5 seconds to reach the desired condition just prior to the forming process.
A three-turn helical coil is used to anneal the steel hydraulic motor shaft. The end of the motor shaft is placed in the coil and power is applied for 20 seconds to reach 1350 °F (732 °C) and turn the steel red hot before machining.
An eight-turn helical is used to heat the aluminum tube for annealing. To anneal the full length of the tube, the tube is placed in the coil and heated, and then the tube is bent while hot to prevent cracking.
To anneal the affected zone of a saw blade after the stellite tips have been welded in place, a split four-turn helical coil is used to allow the blade to move evenly through the coil. Each tip of the blade is heated for 5 seconds as it passes through the coil to anneal the affected area.
To anneal a copper wire used in electric motors, a twelve-turn helical coil is used with an inserted ceramic tube to isolate the copper wire from the coil and to allow the wire to flow smoothly through the coil. Power runs continuously to anneal at a rate of 16.4 yds (15m) per minute.
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...
To anneal a ¼” area around an oval cutout on a stainless steel tube prior to extrusion, 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.
To prepare a wire mesh for press brake bending, induction is used to heat 3” (76.2mm) from the end of the wire mesh 60” (1.52m) long. This provides a faster production process, higher efficiency, lower energy costs and a fast, controllable hands-free process that involves no operator skill.
Induction heating applies heat to very specific areas, faster process time, increased production and high efficiency. In this application, both ends of a copper tube are heated to anneal them as soft as possible 1.5” (38.1mm) from each end, as well as retaining full hardness next to the anneals.
Induction annealing brass provides hands-free heating that involves no operator skill, pinpoint accuracy and consistent results. To anneal a small area of an electrical contact for crimping, a one turn hairpin coil is used to heat the electrical contact to 1000ºF.
Flameless induction heating allows processes - formerly done in batch furnaces - to be done in-line saving time and energy. No rotation of parts is needed.
A three-turn helical coil is used to heat the shaft of the bolts for 10 to 12 seconds on the large bolts and 18 to 20 seconds on the smaller bolts using the same coil. This allows for pinpoint accuracy and repeatability, cycle after cycle.
A three-turn helical coil is used to heat the locknut to 2150°F for 5 seconds. Induction heating provides repeatable, rapid and accurate heating cycles making it ideal for in-line production processes
Induction annealing heats the end of a metal stamp to mushroom instead of cracking/splitting when struck by a hammer. Two helical coils are used to heat the ends to the required temperature. Two part sizes can be run in each of the coils, using the same machine settings except for cycle time.
Induction annealing improves blade quality, decreases scrap product and is easily incorporated into existing production lines. To anneal these stainless steel bread cutting saw blades, a three-turn helical induction heating coil is designed and developed for this application.
A multi-turn induction annealing coil is used to heat various rod diameters. An optical pyrometer is used to measure the temperature of the part inside the induction coil. Initial static tests are conducted, then dynamic tests are run to confirm the results of the static tests
Our bar-end annealing systems provide operating frequencies from 400 kHz for hot-heading of small diameter fasteners to 2 kHz for larger cross-section beams or bars. Systems can be incorporated with pick-and-place robotics to deliver a flameless process,with heating limited to a specific area.
Induction annealing provides higher productivity of 27' (8.2m) per minute, a reduction in surface oxidation & scaling with consistent, repeatable results. Four consecutive coils connected in parallel with a quartz tube lining,are used to heat the wire to 650ºF for annealing.
To selectively and uniformly anneal two sections of a thread ring gage block from the hole to the outside surface from a hardness of Rc 59-61 to Rc 45. Process goals include automation, production rate increase, and elimination of stress cracking resulting from flame heating.
Induction annealing is used to draw-back steel saw blades to a desired Rockwell hardness at a rate of 60 inches per minute. Resulting mean hardness of 50.3 Rc is measured for fifteen saw teeth on a Wilson Superficial Hardness Tester, fulfilling the ultimate goal established by the customer.
Induction annealing heats steel tubes to 2000 ºF (1093 ºC) in an inert atmosphere for very small areas within precise production tolerances. A two-turn concentrator coil is used to heat the stainless steel tube. The annealing process takes place in an inert atmosphere to prevent oxidation.
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About Induction Heating
Induction heating is a fast, efficient, precise and repeatable non-contact method for heating metals or other electrically-conductive materials. The material may be a metal such as brass, aluminum, copper or steel or it can be a semiconductor such as silicon carbide, carbon or graphite. To heat non-conductive materials such as plastics or glass, induction is used to heat an electrically-conductive susceptor, typically graphite, which then transfers the heat to the non-conducting material.
Read our 4-page brochure; learn more about how the science of induction technology can solve your precision heating problems.