This document discusses induction heating in the automotive powertrain industry. It outlines the advantages of induction heating, its current applications, and need for continued advancement. Specifically, it calls for cooperative efforts to improve induction heating education and develop shared resources like material property databases and simulation tools to help design better induction coils and processes.

1. Induction Heating in the Powertrain
Industry
Valentin Nemkov, Robert Ruffini, Robert Goldstein
Centre for Induction Technology, Inc.
Chester Grant, Shekhar Wakade
GM Powertrain

2. 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

3. 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

4. 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

5. Major Applications of Induction
Heating
• Surface Heat Treating
– Hardening
– Tempering
• Sintering
• Shrink Fitting
• Forging and Forming
• Brazing

6. Demand for Improved Induction
Technique
• Existing Equipment is Relatively Old
• Tighter Product Requirements
• Faster “Time to Market”
• Continuously Changing Requirements
• Tougher Environmental Standards

7. Advancements in Induction Technique
• DFIH Strategy
• Power Supplies and Control Systems
• Computer Simulation Tools
• Induction Heating Coils
• New and Emerging Technologies

8. DFIH Strategy
• Material Selection
• Part Geometry
• Heat Treatment Specification
• Sequence of Operations
• Material Handling Equipment

9. 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

10. 2-25 kW HF Power Supply

11. Dual Spindle Camshaft Hardening
Machine

12. 50 kW Power Supply with Portable
Transformer

13. 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”

14. 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

15. Computer Simulation Strategy
3D
2D, Electromagnetic +
Thermal
2D, Electromagnetic or Thermal
1D, Electromagnetic + Thermal
Rule of Pyramid for Induction Heating Computer Simulation

16. Scanning Simulation Using
ELTA

17. Time vs. Temperature Graphs for
the Scanning Process

18. Axle Fillet Geometry
Fluxtrol
Concentrator
Coil Copper
A Water Passage
B Axle Flange

19. Temperature Profile and
Austenitized Zone, 3 kHz

20. 1/4 of a Heat Exchanger Brazing
Coil

21. 3-D Induction Brazing
Simulation

22. 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

23. MIQ Induction Coil

24. ID Hardening Coil

25. Pancake Style Coil

26. Camshaft Hardening

27. Status of Education in the Induction
Technique
• No University Curriculum
• Mainly Self Education
• In-Plant Training
• Generic Induction Heating Seminars
• Emerging New Opportunities

28. New Opportunities for Education
• Computer Simulation and Educational Tools
• Modern Courses and Course Books
• Remote Education via Internet
• International Networking

29. 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

30. 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