Induction Heat Treating Articles & Publications [.pdf format]

Innovative Induction Heating Technologies

Authors: Valery Rudnev, Doug Brown, Gary Doyon
Publication: Proceedings of Material Science & Technology, Conference & Exhibition (MS&T-08), Pittsburgh, Oct.5-9, 2008
Date: 10/5/2008

Presentation focuses on:

  1. Novel approaches to induction heat treating of critical automotive components, including but not limiting to induction contour hardening of spiral, hypoid and bevel gears with diameters from 6" to 8" (patent pending) and sprockets. Patented CrankPro Technology for non-rotational hardening and tempering of crankshafts (V-4, V-6 and V-8) and camshafts with non-convention journals and lobes.
  2. Specifics of induction hardening of hand tools (i.e., wrench jaws, hammers), fasteners, etc.
  3. Induction heating of large-diameter (8 to 12 in. and larger) billets made from carbon steels, stainless steels and Inconel, including a comparative assessment of progressive multi-stage horizontal induction heating approach vs. static heating using vertical inductors (frequency selection, electrical efficiency, system flexibility, cost, etc.).
  4. FluxManager® - technology for effective heating of carbon steel tubular goods (patented in 2007).
  5. Developing compact and highly-efficient induction tempering and stress relieving systems.

Systematic analysis of induction coil failures. Part 13: Electromagnetic proximity effect

Authors: Valery Rudnev
Publication: Heat Treating Progress, Professor Induction Series
Date: 10/1/2008

This article is one of series of articles devoted to a systematic scientific/engineering analysis of failures of induction heating coils and prevention. Electromagnetic proximity effect has a strong influence not only on heating/hardening patterns and unexpected pattern shift but it also effects a coil life being responsible for localized hot spots, copper overheating, degradation, arcing and even melting. Case studies of prevention of premature coil failure due to electromagnetic proximity effect is provided in this article.

Metallurgical insights for induction heat treaters. Part 5: Super-hardening phenomenon

Authors: Valery Rudnev
Publication: Heat Treating Progress, Professor Induction Series
Date: 9/1/2008

This article is one of series of articles devoted to metallurgical aspects of induction hardening and discusses a super-hardening phenomenon. Specifics of induction hardening process and prior microstructure have a pronounced effect on the appearance of the super-hardening phenomenon. Fine grain homogenous normalized structures, as well as quenched and tempered structures have more of a chance to exhibit super-hardening. The phenomenon of super-hardening of induction surface (case) hardened parts is particularly noticeable in steels with a carbon content of 0.35 to 0.65%, case depths less than 0.125 in. (3.2mm) and heat times less than four seconds. The super-hardening phenomenon could allow a user to apply a lower steel grade (lower carbon content) without sacrificing the desired surface hardness and hardness profile of the product. Case study is provided here as well.

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.

Induction hardening of gears and critical components. Part 1

Authors: Valery Rudnev
Publication: Gear Technology
Date: 9/1/2008

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 covers gear materials, desired microsctructure, coil design and tooth-by-tooth induction hardening. Part II, which will appear in the next issue, covers spin hardening and various heating concepts used with it.

Systematic analysis of induction coil failures. Part 12: Inductors for heating internal surfaces.

Authors: Valery Rudnev
Publication: Heat Treating Process, Professor Induction Series
Date: 7/1/2008

This article is one of series of articles devoted to a systematic scientific/engineering analysis of failures of induction heating coils and prevention. Four of the most typical coil failure modes when induction heating internal surfaces of a workpiece (for example, holes or inside diameters)are discussed here. Induction heating of internal surfaces of a workpiece can be used in such applications as hardening, tempering, annealing, shrink fitting, stress relieving, brazing, and others. Ways to prevent premature coil failures and making robast and long-lasting internal inductors are discussed here as well.

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