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Induction hardening of gears and critical components, Part 2

Author: Valery Rudnev
Publication: Gear Technology
Date: 11/1/2008

Induction hardening is a heat treating technique that can be used to selectively harden portions of a gear, such as the flanks, roots and tips of teeth, providing improved hardness, wear resistance and contact fatigue strength without affecting the metallurgy of the core and other parts of the component that don't require change. This article provides an overview of the process and special considerations for heat treating gears. Part I, which was published in the September/October 2008 issue, covered gear materials, desired microstructure, coil design and tooth-by-tooth induction hardening. Part II covers spin hardening and various heating concepts used with it.

Intricacies for the successful induction heating of steels in modern forge shops.

Authors: Valery Rudnev, Doug Brown, Chester J. Van Tyne, Kester D. Clarke
Publication: Proceedings of 19th International Forging Congress, Chicago, IL
Date: 9/7/2008

Over the past three decades, induction heating has become an increasingly popular in forge shops. Among other subjects, this paper discusses:

  • Trends in forging steels. Selection of forging temperatures.
  • Intricacies of process requirements associated with recent knowledge related to theory and practice of induction heating.
  • Novel induction billet heater design concept.
  • Temperature uniformity requirements. Common misassumption.
  • "Stand-by" and "Rapid start" features of modern induction heaters.

Successful Induction Heating of RCS Billets

Authors: Valery Rudnev
Publication: Forge Magazine
Date: 7/1/2008

The induction heating of round bars and round-corner-square (RCS) billets are often treated as equivalent applications, even though they are not. This article reconciles recent theoretical and practical achievements in providing required heat uniformity when inductively heating rectangular and trapezoidal workpieces.

How do I select inductors for billet heating?

Authors: Valery Rudnev
Publication: Heat Treating Progress, Professor Induction Series
Date: 5/1/2008

Induction heating is widely used to heat metals prior to hot forming including forging, upsetting, rolling, extrusion, and other methods. Billets are heated either in cut lengths or continuously and are forged in presses, hammers, or upsetters, or are extruded. Steel components by far represent the majority of hot-formed billets, although other materials including titanium, aluminum, copper, brass, bronze, and nickel are also induction heated for hot forming. The most popular billet-heating approaches are progressive multistage horizontal heating and static vertical or horizontal heating. This column focuses on the advantages and disadvantages of each.

Systematic analysis of induction coil failures. Part 4: Coil copper electromagnetic edge effect.

Authors: Valery Rudnev
Publication: Heat Treating Process, Professor Induction Series
Date: 1/1/2006

Non-uniform coil current distribution resulting from various electromagnetic phenomena has a dramatic effect on induction coil life and crack development in the coil copper. This article is one of series of articles devoted to a systematic scientific/engineering analysis of failures of induction heating coils and prevention. Article concentrates on coil copper electromagnetic edge effect, effect of frequency and coil copper tubing geometry on current density distribution. Other factors that affect electromagnetic edge effect (i.e., flux concentrators, magnetic flux intensifiers, flux controllers, frequency selection, etc.) are discussed here as well.

Systematic analysis of induction coil failures. Part 11c: Frequency selection

Authors: Valery Rudnev
Publication: Heat Treating Process, Professor Induction Series
Date: 1/1/2008

This article is one of series of articles devoted to a systematic scientific/engineering analysis of failures of induction heating coils and prevention. Frequency selection not only affects the performance of the induction system but it also has a significant effect on coil life. Choice of an improper frequency is the most common mistake made by developers and users of induction heating processes. Frequency selection has the detrimental effect on coil life of choosing an improper frequency for induction through-heating applications (including through hardening, annealing, normalizing, and heating prior to hot and warm forming, for example) is the topic of this column and two others in the "Systematic analysis of induction coil failures" series.

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