What type of induction welding is welding?
what type of induction welding is welding? Induction welding is a type of welding that heats the workpiece using electromagnetic induction. The welding machine consists of an induction coil that is energized by a radio frequency electric current. This creates a high-frequency electromagnetic field that acts on an electrically conductive or ferromagnetic workpiece. In an electrically conductive workpiece, the main effect of resistance heating is due to induced currents called eddy currents. In a ferromagnetic workpiece, heating is mainly caused by hysteresis; Because the electromagnetic field repeatedly distorts the magnetic field of the ferromagnetic material. In practice, most materials are subject to a combination of these two effects.
History of Induction Welding
Induction welding was first discovered by Michael Faraday. The principles of this welding explain that the direction of the electromagnetic field depends on the direction of the current flow. And the direction of the field will change with the same speed as the current frequency. For example, an alternating current of 120 Hz changes direction 120 times per second. This concept is known as Faraday law. When induction welding is performed, the workpieces are heated to below the melting temperature and the edges of the parts are stacked, at which time the impurities are forced to form a solid forging weld.
Non-magnetic materials and electrical insulators, such as plastics, can be welded by implanting them with metal or ferromagnetic compounds called sensitizers, which absorb energy in the electromagnetic field from the induction coil, heat it, and conduct it with thermal conductivity. They give their heat to the surrounding materials. Plastics can also be welded by embedding plastic in electrically conductive fibers such as metals or carbon fiber. Induced circulating currents are heated by embedded fiber resistors that lose heat by directing it to the surrounding plastic. Induction welding of carbon fiber reinforced plastics is commonly used in the aerospace industry.
The difference between induction welding and other welds
Induction welding is used for long production periods and is a fully automated process commonly used for welding pipe seams. This can be a very fast process because a lot of energy can be transferred to a local area, so the metal surfaces melt very quickly and can be compressed. The temperature of the metals being welded and their composition also affect the penetration depth. This process is very similar to resistance welding, except that in the case of resistance welding, the current is delivered to the workpiece using contacts instead of induction.
Induction welding applications
This type of welding is used to connect a large number of thermoplastic composites and thermal matrices. The device used for induction welding processes includes a radiofrequency generator, a heating station, and a cooling system. This type of welding is used for longitudinal welding in the pipe industry.
Benefits of Induction Welding
Automatic induction longitudinal welding is a reliable and high-efficiency process. Low power consumption and high efficiency of induction welding systems reduce costs. Their controllability and reproducibility minimize waste. Our systems are also flexible. Automatic load matching ensures full output load in a wide range of pipe sizes. And their small footprint makes them easy to integrate or use in production lines.
Where is induction welding used?
This type of welding is used in the pipe industry for longitudinal welding of stainless steels (magnetic and non-magnetic), aluminum, low carbon alloy, and high strength steel (HSLA), and many other conductive materials.
Top 5 Advantages of Induction Welding
This welding is a high-frequency welding process that involves the use of an electric magnet to generate heat. With this welding, electricity supplies the radio frequency of the induction coil. It heats up as the induction coil receives the electric current. The welding machine can then be used to melt two or more objects together by melting the surface.
Although it requires electricity, induction welding is a very efficient welding process. It requires less electricity than other high-frequency welding processes and is an attractive option for large-scale welding applications such as those performed by manufacturing companies. The machine used in induction welding works electrically, but do not let it get you thinking that it consumes a significant amount of electricity. This type of welding is an efficient welding process that generally consumes less electricity than other welding processes.
2- Concentrated heat
In addition to efficiency, induction welding has the ability to generate concentrated heat. In other words, the heat generated by the induction welding machine is located in a single and specific area and thus the workpiece is protected from damage. This alone makes this type of welding an attractive option for pipes. Water pipes are often connected at the joints using induction welding. The concentrated heat is connected to each other at the joints without damaging the pipes.
3- Supports a variety of materials
From iron and steel to plastics and composites, this welding supports a wide range of materials. Both ferrous and non-ferrous metals can be welded together using this modern welding process. If it is a non-magnetic material, such as plastic, it is usually implanted with ferrous compounds, thus allowing it to absorb the electromagnetic energy produced by the induction welding machine. As long as it contains ferrous compounds, it can be welded using an induction welding machine.
4- Eliminates contaminants
You may be surprised to learn that induction welding can remove impurities from parts. During this high-frequency welding process, the workpiece is heated by the welding machine. As the surfaces of the workpiece are compacted, impurities are removed. In turn, induction welding provides cleaner workpieces than other welding processes.
Although it cannot be fully automated, simple steps in the induction welding process can be performed automatically to simplify the manufacturing company’s operations. For example, load matching can be done automatically to get the right amount of energy to heat and weld parts.
Sources: monroeengineering – wikipedia