Induction in Automotive Manufacturing

Bonding Adhesive to a Steel Washer (Automotive)

Bonding with induction heated a steel washer to the target temperature to enabling adhesive curing; it will be part of an automated process for an automotive industry application

Bonding Plastic with a Steel Gasket

Induction bonding enables rapid heating, can easily be integrated into the client's manufacturing process due to modest space requirements and delivers a highly repeatable process.

Debonding inserts for manifold

A four-turn two-position helical coil is used to debond the inserts from the plastic. The coil is placed against the manifold and power is applied to the two inserts for 15 seconds to soften the plastic...

Sealing a Nylon Shell for a fuel vapor Assembly

Filter modules are assembled on the fixture with ring gasket. Pressure is applied to the modules, modules are rotated and induction heating is started. After 10-12 seconds, heating is halted and the modules are removed from the fixture.

Bonding Rubber Gaskets to a Steel Gas Intake Manifold

Two two-turn pancake coils are specially contoured to the the shape of the steel assembly to produce uniform heat in the gasket areas.

Debond rubber seal from steel oil seal ring

Induction heating provides highly accurate, fast, more efficient placement of heat, no effect to surrounding components

Bonding Automotive Trim Vinyl Covering

Heating to 500 °F is accomplished through the use of the unique coil; molding is continuously processed at a rate over 20 feet per minute.

Press-Bonding Metal Clips Into Sealers

To heat metal clips and press-bond them into rubber seals. The metal needs to be heated to 250 °F to 350 °F with a cycle time not exceeding 3 seconds

Bonding Steel Wire; Rubber Molding

To heat steel wire embedded in an automotive rubber molding. Testing from THE LAB confirmed the feasibility of the heating process for the customer. 

Brazing aluminum adaptors to aluminum tubes

To increase production, a multi-position coil was recommended so multiple parts could be heated while maintaining a cycle time of 55 seconds, delivering consistent joint quality, which a torch often doesn't deliver.

Brazing steel flange and shaft

Induction brazing is a repeatable process that isn't as labor intensive as a flame often is. The process can heat the assembly rapidly and more energy-efficiently than a torch without the safety risks that come with an open flame

Brazing a steel tube and fitting (automotive valve)

Customer's client was unhappy with the results from MIG welding, which drove them to look at induction as an alternative process. Induction heating proved to be a fast, repeatable heating method for the application...

Heat a compacted litz wire bundle for stripping

A three turn helical coil is used for the wire stripping process. The litz wire bundle is placed in the coil for 3 seconds to strip the lacquer 0.75 (19mm) from the end of the bundle. The wire bundle is then scraped with a metal brush to remove the burnt lacquer...

Heat aluminum for brazing an automotive assembly

A multi turn pancake coil is used to heat the joint between the aluminum tubing and boss. The joint heats to temperature in 1.5 minutes and the braze ring melts forming a clean brazed joint.

Brazing automotive tube assemblies

A four turn split helical coil is used to heat the steel assembly to 1400 °F (760 °C) for 85 seconds. The coil design allows for the steel fitting to expand away from the steel tube which allows braze to flow through the joint.

Braze a Copper Tube and Brass Fitting

How to braze copper using a custom-designed single position multi-turn helical coil built to generate the required heating for the copper brazing application.

Brazing Oil Suction Assembly with Copper Ring

To heat an oil suction assembly (steel tubing and filter cap) to 1,850 °F (1010 °C) within 15 seconds for a brazing application.

Brazing an Aluminum Tube Assembly

A custom-designed single position multiple-turn pancake coil was built to generate the required heating for this brazing application. Initial tests were conducted to optimize power delivery to the assembly

Curing a coating; both sides aluminum piston

A three-turn channel coil 19 in (48.26 cm) long is used to anneal 4 pistons running though the coil with a distance of 6 in (15.24 cm) between centers.

Curing plastisol adhesive on an aluminum filter assembly

A four turn helical coil is used to cure the plastisol adhesive. One filter end cap is filled with adhesive, attached to the filter and heated 90 seconds to cure the adhesive.

Bonding Rear View Mirror Brackets to Windshield Glass

A unique four-over-four double wound pancake coil is used for the bonding application.

Curing Adhesive on Steel Motor Shaft for Bonding

A complex two coil system, shield and stud systems used to provide proper axial alignments of the shaft & coil while allowing the fixture to be open for removal of the shaft.

Heating Aluminum Auto Trim for Adhesive Curing

To heat various sizes of aluminum auto trim to 500 °F (260 °C) at a rate of 30 ft. (9.1m) per minute for curing an adhesive.

Heating stainless steel inserts

Induction offers dramatically faster heating when compared to ultrasonics; faster heating means there is the potential to dramatically increase production rates with a highly repeatable and easy-to integrate processes.

Heating brass inserts

Innovation: Ambrell's Applications Lab was able to solve a problem that a competitor couldn't solve, which is a key benefit when purchasing induction solutions from Ambrell

Metal-to-plastic insertion of threaded magnetic steel inserts

Outdated equipment and poor responsiveness drove this customer to a new vendor who could help them with new or improved processes for new or enhanced solutions

Inserting a piston stop & o-ring (oil pump)

Induction heating provides increased production speed, simpler tooling for customer, hands-free heating that involves no operator skill for manufacturing

Bonding electric motor shaft to nylon face fan

Induction heating provides hands-free heating that involves no operator skill for manufacturing, only the metal shaft is heated so the motor is not affected, increased production due to rapid heating, decreased failure rate, originally used glue which ran into motor and caused failure and stronger bond

Heating Four Inserts Simultaneously

The brass inserts are to be heated prior to insertion into a plastic automotive sub assembly

Brass Inserts

Heating is to be accomplished within 5 seconds, and can be done in a helical coil since pick and place manufacturing is employed.

Inserting Steel Studs into a Plastic Tail Light

To heat threaded steel studs for insertion into a plastic tail-light assembly at 450 °F.

Metal-to-Plastic Insertion with a Steel Insert

The power was turned on for five seconds and the part was monitored during heating and for 15 seconds after.

Heat Staking Steel Parts

To heat steel inserts to be placed into a plastic frame. The end product is an automotive part. 

Heating a Steel Pin for Fan Insertion

An EASYHEAT and its workhead require a minimal footprint, saving the client valuable floor space compared to heating alternatives

Heating an Aluminum Tube for Bending

Induction does not present an open flame into the work environment like a torch, resulting in a safer working environment

Heating stainless-steel inserts

Induction heating offers dramatically faster heating compared to ultrasonics which means dramatically increased production rates. Induction is highly repeatable and easy-to-integrate into manufacturing processes.

Preheating a steel automotive transaxle (welding)

The steel axle was painted with temperature indicating paint and a thermocouple was attached to the part.

Pre-heating aluminum wheels (spray painting)

This spray painting application requires pre-heating the material. Additionally, there is a requirement that the material must not cool below a certain target temperature prior to the spray.

Heating lead battery terminal for removal (recycling)

A single turn helical coil is used for this heating application. The lead terminal is placed inside the coil and is heated for 20 seconds.

Heating a motor prior to adding an injection molded part

Induction heating enables quicker process times with increased production rates versus a gas-fired oven. Ovens require long heat-up and cool-down times

Heating steel liners (engine head)

Precise direct heat to disengage the aluminium quickly and cleanly. The aluminium casing is recycled and reused thereby reducing scrap and cutting costs.

Heat automotive seat springs to powder coat

Even heating of the spring before dipping provides uniform flow and provides consistent thickness of the nylon coating

Heating of steel rivet ends (turbines)

Heating steel rivets prior to head forming

Heat the end of catalytic converter for weld testing

Heat the end of lorry catalytic converter exhaust system. The assembly must be held at target temperature for 200 hours, whilst the assembly is vibrated to test the weld strength

Heating Automotive Battery Cables for Adhesive Melting

Temperature indicating paint was applied to the parts, and it took 10 seconds to heat the various styles of the part to the targeted temperature. This testing achieved the client's time and quality objectives.

Heating an Engine Valve Head for Stress Testing

To heat the face of an engine valve head to 900 °F and maintain the temperature for an extended time, high temperature stress test.

Pre-heating a Truck Axle Seam for Welding

To pre-heat the seam of a truck axle to over 300 °F within 15 seconds for a welding application and maintain temperature within the welding zone

Preheating Steel Laminate Parts

The c-lams are inserts for an automotive industry application. In production the robotic pick-and-place will occur for plastic overmolding after heating by induction.

Preheating Rod Assemblies for Welding

The client had been using torches for preheating. However, due to process improvements thanks to new automation in their facility, torch heating became too slow. This resulted in a backlog that kept them from maximizing their throughput.

Pre-heating a steel transaxle tube (welding)

Induction heating achieves an identical result consistently, and is a more efficient heating method, each of which are advantage over torch heating

Preheating Steel Tubes Prior to Bonding

To heat steels tubes for a bonding application; the end product is a bushing for large trucks. Induction would replace an oven for this client. 

Shrink fitting an automotive aluminum motor housing

Induction shrink-fitting is fast, presents significant energy savings over an electric oven, requires a more modest footprint than an oven and can be easily integrated into an automated process

Shrink Fitting A Gear to a Shaft

The customer was using a torch, which can lead to inconsistent part quality. Induction's precise heating means the client can count on consistent results in their process

Shrink Fitting an Aluminum Motor Housing

The customer was using a cold press, but it was creating part defects. This was resolved with induction heating: the process took just two minutes compared to 40 minutes and they were able to achieve their targeted production rate.

shrink-fitting a carbide ring into a valve seat

A three turn helical coil is used to heat the steel valve seat. The steel valve seat is placed in the coil and heated for 50 seconds to enlarge the center hole & drop the carbide ring in for the shrink-fitting process.

Shrink-fitting auto turbo charger impeller blades onto an aluminum shaft

Induction heating provides repeatable results, reduced cycle time, lower consumables cost and even distribution of heating

Shrink fitting aluminum pulley to insert inner bearing

A three turn helical coil is used to heat the aluminum pulley. The pulley is heated to 464 °F (240 °C) in 20 seconds to expand the inner diameter and then the inner bearing is inserted to form the completed part.

shrink-fitting an assembled wrist pin into a connecting rod

Induction heating provides more accurate control of heat vs a flame burner, it heats only the knuckle, not the whole part, it prevents discoloring due to lower temperature used and increases productivity due to repeatability & ease of operation. A foot pedal & timer is used.

Shrink fit a motor shaft and roller

Processing with induction heat saves power and time. The complete tube does not have to reach the desired temperature as it does when heating with an oven. Being able to selectively heat a zone allows for a much quicker transfer of heat.

Shrink Fitting Cam Shaft Gears

To heat aluminum and steel camshaft gears to over 500 °F within 4 minutes for a shrink fitting application.

Shrink Fitting Magnetic Steel Pistons

Using induction for shrink-fitting magnetic steel pistons onto a chrome shaft; the client was using an unreliable handheld induction system and wanted a higher quality induction shrink-fitting solution.