Induction hardening technology doesn’t use physical contact. Instead, a series of magnetic fields are projected from a large coil. Workpieces enter the coil, experience this induction effect, and respond by generating surface heat. That workflow suggests a production line of some kind. If so, is its ever-cycling configuration preferred over, say, flame or case hardening technology?
High-Volume Processing
In order to answer that query, consider the alternative. A focused flame functions as a targeted hardening method. The technique heat treats gear teeth and other finely wrought geometrical profiles. Even large surface areas can be scanned and hardened via a traveling flame nozzle. Still, it’s not considered a large volume solution, not one that can compete with induction hardening. Down on a fast-moving factory floor, the inductance effect slots neatly into a fast production environment because it’s able to accommodate a fast processing run while delivering a cheap and repeatable final result.
One-Shot VS. Traverse Hardening
The frequency-modulated coils act as an efficient one-shot hardening mechanism, a configuration that perfectly matches the dimensional profiles of axles and shafts. The longitudinal metal segments submit readily to the lines of magnetic energy, with the induced currents forming strong thermal tides that flow naturally along the long metal segments. Alternatively, a traverse mechanism can replace the one-shot methodology. In this case, the part is moved progressively into the coils. This layout suits a standard production line, with the parts moving from one stage to the next. In keeping with this mechanical configuration, a spray quench ring is typically activated at the end of the part’s treatment.
Fine-Grain Parts Treatment
The option to longitudinally vary the frequency or applied power in different sections of the induction coil makes this method a highly tunable technique. Even the velocity of the traverse mechanism subscribes to this work model, with the component slowing to experience additional depth hardening on specified sections. Indeed, processed pins, axles, and shafts are imbued with specified heat treatment profiles after they depart the induction treatment mechanism. That’s because the station is designed to accommodate longitudinal workpieces and to process each one with repeatable mechanical features, all while maintaining a high-volume work throughput.
A contactless hardening profile can reach down as far as 15-mm when induction technology is added to the production line. The long, cylindrical coils are perfectly configured for pin processing, axle hardening, and cost-effective shaft processing. Finally, all of this one-shot and traversing momentum assumes a cycling manner, a flow that’s guaranteed to repeatably process these long parts through ring-type coils while imprinting them with localized attributes that are as hard as any flame or case hardened solution.
The flame hardening process functions as an exceptional surface hardening solution. Its gas-generated flame hardens selected areas on command, then switches tact to heat treat large surface areas, no matter how eccentric the part’s geometry becomes. Let’s indulge in a little discrete analyzing, a look into flame hardening and the method’s gift for processing large and uniquely profiled parts.
Large-Scale Processing Suitability
An accelerated workflow is a prominent feature here, an upshot of the flame hardening method that assures wholesale depth-hardening, even when the workpiece surface is massive. In order to achieve the faster process times, a sweeping (scanning) flame head is used. It moves across sizable surface areas to assure full surface transformation. The shape of the flame head, the gas used, and the ability to focus the heat all contribute to this large-scale heat treatment faculty, with some uniquely innovative mechanical assets supplementing the mobility of the tooling assembly.
Utilitarian Workflow Benefits
Due to the streamlined tooling set-up, the equipment sports an optimized frame, a configuration that’s more cost-effective than some of the comparable hardening techniques we’ve mentioned so far. The versatile flame head adapts to complement the project, which means it opens up and scans to process massive parts, but that workflow is adaptable. Focusing adaptability sharpens the gaseous output and targets that fiery edge so that it can process gear teeth and other fatigue susceptible components until they’re fully surface-crystallized and rated as a toughened martensitic grain.
Transforms Eccentric Profiles
We’ve compared flame hardening methodologies to induction techniques with good reason. Essentially, they both use currents of energy to transform (harden) the surface of an alloy. But induction technology, as beneficial as the method undoubtedly is, relies on magnetic effects. Flame hardening, on the other hand, uses currents of pure thermal energy, burning gasses that precisely target gear teeth and other finely detailed work parts. As a result, the focused fire penetrates bore holes and all kinds of complex geometrical outlines predictably, without ever causing an engineer to worry about some hard-to-predict electromagnetic parameter.
If the reassuring presence of a controllable flame isn’t enough to determine this heat treatment method as an upper-echelon hardening solution, take note of the other benefits that accompany the process. Tooling requirements are straightforward, so costs are lower than a comparable induction set-up. Partner this shorter system tooling period with faster parts processing times and an ability to adapt to large-scale or focused processing and, well, the flame hardening method can be considered the equal of any induction hardening solution.