Resistance Welding and Induction Heating Machines – A Full Overview

In the past few years, Induction Heating Machines have become one of the major equipment for welding purposes in various industries which has increased their use drastically. The welding equipment manufacturers have also made this equipment readily available in the retail market. Essentially, the induction method is preferred due to its ability to heat the metal faster than any other traditional electrical resistance method. This is highly efficient for a post-weld heat-treat cycle or shaft hub to remove it easily.

Professional heat-treatment companies with fleets of heating machines rarely use induction equipment for welding. The key reason is? temperature control, equipment durability, and equipment capacity. The pre-weld and post-weld heat treatment are important for various welding activities. Without the appropriate thermal manipulation, welded areas and heat-affected zones may turn into undesirable mechanical properties.

Although several industries have been using the Induction Heating method for decades, it is still a novice in the welding applications for industrial and construction purposes. Some companies involved in welding demanding operations make use of Induction Heating Machines?to pre-heat before welding and post-heat after welding.

What Is Induction Heating And What Are Their Applications?

Introduction

With Induction heat welding, the heat is induced into a workpiece with the science of electromagnetism. The accuracy and speed of Induction heating make it absolute for welding the edges of pipes and tubes. This method includes an induction coil that passes through the pipe at high speed. While doing so, the edges get heated and then compressed together in a form of longitudinal weld steam.

The Induction Welding method is essentially suitable for mass production. The Induction Heating Machine Suppliers also fit the contact heads to turn them into a two-sided welding setup. The Induction Welding systems can vary as per the application setup, but our Resistance Welding Machine Suppliers have all the necessary equipment required for any common scenario.

Applications

Time and time again, Induction Welding technology has proved itself to be worthy of numerous projects. It is heavily used in the pipe and tube industry for the longitudinal welding purposes of stainless steel (either magnetic or nonmagnetic), low carbon, aluminum, and highly-durable low-alloy (HSLA) steels, and other such conductive materials. including:

  • Oil Pipelines
  • Natural Gas Pipelines
  • Heavy Equipment
  • Mining Equipment
  • Power Plant

Benefits of Induction Heating

Automated Induction Welding Machines are reliable for their high-throughput operations. The high efficiency and low power consumption of our Induction Heating Machines are cost-effective. The repeatability and controllability reduce the scrap formed. We have flexible systems that load the machines automatically ensuring maximum power throttle across a greater range of the side of the tube.

It is much easier to integrate or reconstruct the production lineup. Therefore, induction heating can bring numerous advantages to the industry that includes uniform heat production and quality, long-lasting consumables, and lesser cycle time. The induction Heating method is also reliable, safe, power-efficient, easy to use, and versatile.

Reliability

One of the most key factors that impact productivity in relieving stress is having an uninterrupted cycle. In most cases, interruptions during cycles imply that you need to rerun the heat treatment. It is significant when the thermal cycle takes the whole day to complete one cycle. The components of the Induction Heating Machine make it unlikely for cycle interruptions. The cables used for induction are simple which makes it less likely to run into failures. Plus, contacts are not used for heat input control to the part.

Power Efficient

The power source of the inverter is 92% efficient, which is a major advantage in a world where the cost of energy is skyrocketing. In addition to that, the process of induction heating is 80% more efficient. As far as power input is concerned, the process of induction heating requires just a 40-amp line for 25 kW of power.

Easy To Use

A major advantage of relieving stress and pre-heat induction is its simplicity. Cables and Insulations have easy installation processes that generally take less than 15 minutes. It is so simple that the process of using induction equipment can be learned in one day.

Quality and Uniformity

Induction heating machines are not specifically sensitive to spacing or coil replacement. Typically, the coils must be centered and evenly spaced over the weld joint. On clustered machines like these, a temperature controller can provide a power source in an analog form, giving it just enough power to sustain the temperature. The power source establishes power throughout the process

Versatility

While using induction heating machines for preheating and stress relieving pipe, users have adopted the process of valves, weldolets, elbows, and other things. One of the major aspects of Induction welding heating that makes it highly beneficial for complex shapes is its ability to adjust the coils during the process of heating. It adjusts the heat sinks and other unique parts. The user can begin the process, calculate the effects of the heating process instantaneously in-real time, and adjust the position of the coil to change the output. The induction cables can be modified or adjusted without waiting for them to cool by air by the end of the cycle.

Cycle Time

The pre-heat and stress relief Induction Heating method provides a relatively faster time-to-temperature. For thicker operations like high-pressure steam lines, induction heating can lower 2 hours from the cycle time. Thus, it is possible to slash the cycle time from temperature control to the soak temperature.

Safety

Stress-Relieving and Pre-Heating through the Induction Heating Welding Method is operator-friendly. This process does not require hot connectors or heating elements. Very less airborne particles equate with the insulation cables. The insulation itself aren?t opened to temperatures going beyond 1,800 degrees which causes the insulation to get compromised that workers may inhale.

Consumables

The insulation material used by Induction Heating Machine Supplier?and Resistance Welding Machine Supplier?altogether is easy to attachable and detachable to the appliances that can be used multiple times. Additionally, induction coils are durable and robust, so they don?t require fragile wire or materials made of ceramic. Also, since the connectors and induction coils are not exposed to high temperatures, they are not subject to deterioration.

Conclusion

With more use of thin-wall steel alloy pipes in the gas and oil pipeline industry, Heating and Welding machine suppliers are switching to faster, uniform, and accurate Induction Heating Systems. You can visit our website to know more!

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