How Induction Forging Works

Induction forging combines precision, control, economics and safety, focusing heat only on the portion of the material to be forged, efficiently producing the malleable temperature.

Induction Forging Offers numerous Benefits

Rapid heating for improved productivity and higher volumes
Precise, even heating of all or only a portion of the part
A clean, non-contact method of heating
Safe and reliable – instant on, instant off heating
Cost-effective, reduces energy consumption compared to other heating methods
Easy to integrate into production cells
Reduced scaling

Due to induction's inherent precision and control, there’s no risk of an incorrect temperature resulting in the wrong shape or risking damage to the tools that are used in the following step of production.

Forming a Large Steel Tube

Heating an area around elliptical hole in steel tube prior to forming; the client had been using a torch for this application.

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 Cutting Tools for Forging

An infrared pyrometer was used to monitor the temperature of the part during the heating cycle. Two parts were tested.

Flattening/Bending Steel Tubes

Induction heats the tubes to forging temperature much more rapidly than an oven, targeting the precise portion of the part that requires heating every time, presenting a significant advantage over an oven

Forming a Magnetic Steel Part

Induction heated the part to forming temperature more rapidly than a torch. Induction targets the precise portion of the part that requires heating every time

Forging a magnetic steel rod

Testing determined that the magnetic steel rod heated to required temperature within 1.5 seconds with an EASYHEAT LI induction heating system.

Forging silver bars to create collectible coins

The client had been using an oven, and induction can present some speed advantages. Unlike an oven, induction offers instant on/instant off heating

Preheating steel rods for forging in a fastener manufacturing process

The client targeted an aggressive cycle time, achieve thanks to our process design and the efficiency of induction heating; fast heating means greater manufacturing throughput

Forging rods of various materials and dimensions

Each of the rods were placed into the coil and heated. They achieved the targeted temperature in 30-40 seconds. The coil was designed for a 5 (127 mm) heat zone.

Preheating a brass rod for forging

The client wanted to cut the cycle time it was getting from a torch in half, and the Ambrell induction process was able to meet that goal.

Preheating a billet for forging

The client needed to improve the cycle time of their gas furnace, and by preheating it prior to insertion into the furnace, time was saved and the client didn't have to invest in doubling the size of their furnace.

Preheating a brass assembly for forging blanks

The client was using a competitor's system, and it was heating the assembly at a slower rate. They needed to increase their production rate, which this solution was able to achieve.

Preheating steel rods for forging in a fastener manufacturing process

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

Preheating for forging of steel pins

Fast, precise heating of the pin - 2 minutes and 36 seconds were saved on heating all of the rim's pins when compared to using a torch

Preheating titanium rods for forging turbine blades

Induction heating provides increased production rates, repeatable, reliable & consistent heat without flame and hands free heating that involves no operator skill for manufacturing

Pre Heating Mold Release Push Rod For Forging

To heat the ends of steel rods to 1800°F 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 heating in a channel coil to temper the rods and relieve the forging stresses.

Heating Inconel Billets for Forging

A four-turn helical coil is used to deliver uniform heat to the inconel billets. Both size billets heat to 2050°F (1121.1ºC) within 12 seconds.

Pre Heating Steel For Forging Horse Shoes

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

Important Forging Considerations

Size of the Heated Part

In addition to the amount of energy required to heat the part to the forging temperature, the size of the part will also dictate the required operating frequency of the induction system to optimize operating efficiency.

Time for Through Heating

The induction process produces heat within the part, but the heat is generated near the outside surface and will take time to conduct to the center of the part. Typically, bar ends up to 20 mm in diameter through-heat in less than 10 seconds, whereas a 75 mm diameter bar will take 150 seconds to heat to the center.

Radiation Loss

Energy loss due to radiation from the hot part becomes significant with forging temperatures in the 1000 °C (1832 °F) to 1200 °C (2192 °F) range and can be controlled by using thermal insulation during the manufacturing of the induction coil.

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.