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 +
Thermal
2D, Electromagnetic or Thermal

1D, 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

Fluxtrol
Concentrator

Coil Copper

A Water Passage

B 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