Induction hardening is a popular method of surface case hardening which strengthens and improves the wear resistance of components and parts. By means of induction hardening technology, the induction heaters induce electromagnetic field to the parts or components. The heat is generated by the eddy currents in the material, then a quenching media such as oil is used to cool down the parts rapidly, thus a case hardened layer can be created generated by these processes.
Induction heating technology is usually chosen for its high efficiency and precise control compared with other hardening methods. Usually the combination of induction heating, induction hardening, and quenching media is used to achieve correct heating and cooling results which are the keys of the successful induction hardening.
The parameters of induction hardening machines are varied depending on the size, shape, hardness and application of the components and parts to be treated. Generally, induction hardening machines are classified as continuous, manual, and touch-screen machines accordingly. The more advanced induction hardening machines are consist of components such as inductor, power supply, controllers, cooling system, quenching media, etc.
The inductors are an important component of induction hardening machines for providing and converting power with suitable frequency, shape, size and power. The shape of the inductors can be adjusted according to different application, e.g. polygonal, circular, or single and double seals, etc. The size of the inductor is dependent on the inductee.
The power supply of the induction hardening machine provides the electric energy and directs to proper inductors and to the inductee accordingly. The frequency selection is also depending on the inductors shape and size, most induction hardening machines are operated with a frequency range from 10kHz to 500kHz. The power output of the induction hardening machine depends on the size, shape and application of the inductee.
The controllers of induction hardening machines are the heart of the machines, they direct the actions and control parameters such as power, frequency, and temperature. The controllers also monitor and adjust these parameters according to the real time requirements of the inductee.
The cooling system is another important component of induction hardening machines, it brings the quenching media to the component to decrease the components temperature and thus creating the case hardened layer. Most induction hardening machines are using oil as the quenching media, but water-based solutions and air can also be used.
All the components mentioned above are important for the successful induction hardening process. The parameters, such as the size and shape of the inductor, power supply and output, frequency, and cooling media are selected depending on the application and parts to be treated. The controllers should be carefully adjusted and monitored to achieve consistent and accurate hardening results.
In short, induction hardening technology is an efficient and precise technique of surface case hardening. Its parameters such as inductor shape, size, power output, frequency and cooling media should be suitably selected accordingly. It is a complex process but with correct parameters and proper operation, a successful result can be achieved.
