Induction Heating in the Powertrain Industry

Valentin Nemkov, Robert Ruffini, Robert Goldstein Centre for Induction Technology, Inc.

Chester Grant, Shekhar Wakade

GM Powertrain

Overview

• Advantages of Induction Heating

• Status of Induction Heating in the Powertrain Industry

• Advancements in the Induction Technique

• Education in Induction Heating

• Need for Cooperative Efforts

Advantages of Induction Heating

• Short Heating Cycles and High Production Rates

• Better Metallurgical Results

• Good Control and High Repeatability

• Small Surface Oxidation and Decarburization

• Low Distortion

• Favorable to the Industrial Environment

Status of Induction Heating

• Widely Used in Powertrain Industry

• Relatively Old Equipment and Technology

• Relatively Short Coil Lifetimes

• Depletion of Experienced People

• Demand for Improved Induction Technique

Major Applications of Induction Heating

• Surface Heat Treating

– Hardening

– Tempering

• Sintering

• Shrink Fitting

• Forging and Forming

• Brazing

Demand for Improved Induction Technique

• Existing Equipment is Relatively Old

• Tighter Product Requirements

• Faster “Time to Market”

• Continuously Changing Requirements

• Tougher Environmental Standards

Advancements in Induction Technique

• DFIH Strategy

• Power Supplies and Control Systems

• Computer Simulation Tools

• Induction Heating Coils

• New and Emerging Technologies

DFIH Strategy

• Material Selection

• Part Geometry

• Heat Treatment Specification

• Sequence of Operations

• Material Handling Equipment

Power Supplies and Controls

• Solid State Power Supplies

• Small Size and Weight

• Higher Efficiency

• Greater Adaptability and Controllability

• Faster Response Times

• Intelligent Control Systems

• Process Monitoring and Recording

2-25 kW HF Power Supply

Dual Spindle Camshaft Hardening Machine

50 kW Power Supply with Portable Transformer

Benefits of Computer Simulation

• Faster Process Development

• Accurate Results

• Demonstration of the Entire Dynamics of the Process

• Leaves Records for Future Study

• Improves Knowledge Base

• “Human Factor”

Computer Simulation Uses

• Education and Self-Education

• Research and Development

• Case Studies

• Process and Equipment Design

• Advertisements and Business Presentations

– See more about software on www.induction.org

Computer Simulation Strategy

3D

2D, Electromagnetic or Thermal

1D, Electromagnetic + Thermal

2D, Electromagnetic +

Thermal

Rule of Pyramid for Induction Heating Computer Simulation

Scanning Simulation Using

ELTA

Time vs. Temperature Graphs for

the Scanning Process

Axle Fillet Geometry

A

B

Fluxtrol

Concentrator

Coil Copper

Water Passage

Axle Flange

Temperature Profile and

Austenitized Zone, 3 kHz

1/4 of a Heat Exchanger Brazing

Coil

3-D Induction Brazing

Simulation

Induction Heating Coils

• Better Coil and Process Efficiency

• More Precise Heat Pattern Control

• New Materials for Magnetic Flux Control

• Longer Coil Lifetimes

• Coil Manufacturing Technology

• Computer Assisted Design

MIQ Induction Coil

ID Hardening Coil

Pancake Style Coil

Camshaft Hardening

Status of Education in the Induction Technique

• No University Curriculum

• Mainly Self Education

• In-Plant Training

• Generic Induction Heating Seminars

• Emerging New Opportunities

New Opportunities for Education

• Computer Simulation and Educational Tools

• Modern Courses and Course Books

• Remote Education via Internet

• International Networking

Industry Collaboration

• Group Development of Basic Technologies

• Development of System for Education

• Development of Teaching Tools

• Development of Focused Computer Simulation Programs

• Development of Material Property Database for Induction Heating

Conclusions

• Induction Heating Is Not Being Used to It’s Full Potential

• Many Old Processes and Equipment are Obsolete

• Induction Personnel Require Education and Knowledge Updating

• Cooperative Efforts are Required in:

– Education

– Material Property Database

– Improved Induction Coil and Process Design