Induction
hardening offers significant advantages over traditional
methods for heat-treating steel, alloy, and other metal parts. This process is
perfect for metal with a carbon content of more than 0.3%, particularly
hardened steel with a low alloy content (C34, C35, C60, etc.), as described in
the DIN EN 100083 industry norm. Shafts, gears, armatures, sprockets and other
components can all be hardened using this induction process.
The process is very demanding on the equipment
and the inductor used. Ideal hardening results can only be achieved by
perfectly matching a precisely controlled energy source with an optimum
inductor design. eldec's experienced engineers custom design the induction
coils to meet customer unique specifications, including single turn, two-turn,
face-heating, clamshell, and clamp inductors. Every machine is completely
inspected and tested to ensure optimum power and heat settings.
Heating directly with induction hardening
Induction
hardening in Faridabad is a process in which the heat is generated
directly in the work piece. The principal advantage of this type of heat
treatment is that the material quickly reaches the desired temperature to
produce hardened metal parts. With traditional heat treatments such as flames,
ovens, or by convection, heat is applied to the part by heating up the surface
layer. These methods take considerably longer and require significantly more
energy to produce the desired hardness. Induction hardening, by contrast,
offers extremely short heating times. It is a very effective and attractive
method in the manufacturing of steel shafts, components, and other metal parts
across a range of industries. Additionally, induction heating can be very
precisely controlled via the power, frequency, and inductor geometry. This
minimizes deformities in the workpiece and ensures the efficiency of the
process.
How induction hardening works
The primary application of this induction
method is the hardening of steel. One or many induction coils are used to
generate and target an alternating magnetic field. This magnetic field produces
eddy currents in the metal, which heat the workpiece up to the desired
temperature. Immediately after heating, the component then goes through a
quenching process using water, oil, or an emulsion. This cools the metal until
martensitic transformation occurs, producing a hardened surface that is tougher
than the base metal.
After quenching, the steel undergoes tempering,
a low-temperature heat treatment process, to reach the desired hardness /
toughness ratio. The maximum hardness of a steel grade obtained through the
hardening process gives the material a low toughness. Treating the steel
through tempering reduces the hardness in the material and increases its
toughness.
The hardening depth in the work piece is controlled,
very precisely, by adjusting the electrical power output of the induction
machine and the frequency of the inductor / coil current. The thickness of the
heated layer from the surface of the metal to some point below the surface is
inversely proportional to the frequency of the applied alternating current.
Higher frequencies produce thinner skins. Case
hardening in Faridabad the surface of steel increases the wear
resistance of the component without reducing the ductility of the bulk of the
material. eldec offers energy sources with the latest converter technology in
three frequency ranges:
- Low: 1 – 7 kHz
- Medium: 8 – 40 kHz
- High: 60 – 500 kHz
Induction hardening with SDF
With Simultaneous Dual Frequency, also known as
SDF, eldec offers an additional method that is used especially for work pieces
with complex shapes. A medium frequency is overlaid with a high one so that
both act upon the material simultaneously at a uniform depth. This guarantees
the component is heated at a consistent temperature across the entire part to
ensure even surface hardness. This application is perfect for the process of
manufacturing cogs and gears. Even though the top and bottom of the gear teeth
are at different distances from the inductor, a smooth and precise hardness
layer can be achieved.
