Induction in Fastener Manufacturing

How is induction heating used in fastener manufacturing?

Production rates are improved using induction to heat the fasteners for heading, thread rolling and thread patching processes. Fasteners are heated quickly, efficiently, and with maximum repeatability.

Induction generates an electromagnetic field in a work coil that induces currents in the conductive material of a workpiece placed within or near the coil. Friction from these currents elevates the temperature of the fasteners being heated.

Benefits of induction in fastener manufacturing

Induction heating meets tight production tolerances with precise localized heat to small areas creating pinpoint accuracy, while increasing production rates with faster heating cycles. It reduces defect rates with repeatable, reliable heat and eliminates variability from operator-to-operator, shift-to-shift. Induction also maintains metallurgical characteristics of the individual metals.

Annealing

Band annealing on Titanium fasteners

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.

Annealing Copper Wire Connectors

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.
Forging

Preheating steel rods for forging 1

The client targeted an aggressive cycle time, which Ambrell was able to achieve thanks to its process design and the efficiency of induction heating

Pre Heating Mold Release Push Rod For Forging

To heat the ends of steel rods to 1800 °F using induction prior to a forging operation. Processing of the rods includes heating, pressing in a two part die to forge the push rod end, and a final induction heating in a channel coil to temper the rods and relieve the forging stresses.

Pre Heating Steel For Forging Horse Shoes

Induction forging provides for hands-free heating that involves no operator skill for manufacturing, improved production rates with minimal defects, low pressure and minimal residual part stress with even distribution of heating

Hot Heading Steel Wire: Create Screws

Preheating steel wire before hot heading to create a screw; they wanted to switch from cold heading to extend tool life.
Heating (Others)

Pre-heating single rod for hot heading

A seven-turn helical coil is used to heat the rod. The rod is placed inside the coil and power is applied for two seconds providing enough heat to penetrate the inner core

Heating stainless steel rod for hot forming

Induction heating provides for hands-free heating that involves no operator skill for manufacturing, improved production rates with minimal defects, low pressure and minimal residual part stress with even distribution of heating

Stainless Steel 'J' Tape

Induction heating provides for hands-free heating that involves no operator skill for manufacturing, improved production rates with minimal defects, low pressure and minimal residual part stress with even distribution of heating

Heating rods for thread rolling to create fasteners

This is part of an automated line. The system was sized and the coil was designed to ensure 45 parts per minute can be heated to the temperature required for hot forming.

Heating threaded area of fastener

Induction heating is localized only to the threaded area, decreases production time with a flameless process and delivers even distribution of heating

Heating fastener blanks for thread rolling

Induction heating provides faster cycle times and extended tool life with preheat step, fands-free heating that involves no operator skill for manufacturing

Heating a 10mm Diameter Steel Wire

Heating the customer's 10mm diameter steel wire to 400 °F (204 °C)
Hot Heading

Heating Steel parts for hot heading

Induction heating provides hands-free heating that involves no operator skill for manufacturing, direct application of the heat on the work piece with precision and consistency, even distribution of heating with low pressure and minimal residual part stress

Heating wire for hot heading

Induction heating provides hands-free heating that involves no operator skill for manufacturing, elimination of springback effect, extended die life, better grain flow and microstructure with even distribution of heating

Pre-heating three rods for hot heading

Induction heating provides improved production rates with minimal defects, reduced need for post production tempering and heat treating and even distribution of heating

Why use induction for fastener heating?

To improve production rates and fastener quality, fastener manufacturers use heat in their heading, threading and patching production processes. With induction heating, fasteners are heated quickly, efficiently, and with maximum repeatability.

Is induction appropriate for hot heading?

Induction heating is commonly used for preheating bolt and screw heads prior to forging, offering many benefits for the warm or hot heading processes.

Can it be used to cure paint or powder?

Induction heating is ideal for curing the paint or powder material used in thread patching. It can greatly improve thread patching productivity by rapidly heating fasteners up to 300° C for flowing the paint or powder coating.

What is thread rolling?

Thread rolling pushes the material into shape against a thread roll die rather than cutting, thus reducing material waste and stress to the fastener. Thread rolling produces a higher quality product than cutting.

Can induction be used for thread rolling?

Induction heating can easily be integrated into the thread rolling production process and has proven to be a more rapid and consistent method of heat that leads to superior repeatability and increased production efficiency in high-volume parts manufacturing.

10 Induction Heating Application Notes

We have collected these 10 popular Application Notes to help you understand the many ways induction heating can improve your heating processes.

10 Automotive Application Notes

We have collected these 10 popular Application Notes to help you understand the many ways induction heating can improve your precision automotive manufacturing processes.