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Induction Hardening of Steels :: Total Materia Article
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Induction Hardening of Steels
Although relatively complex and involving a series of processes, induction hardening offers an extremely energy efficient (up to 95% savings) heat treating operation.
Te three most common forms of induction hardening are surface hardening, through hardening, and selective hardening. Surface hardening for example is a key hardening process in automotive components.
Hardening of steels and cast iron represents te most popular application of induction heat treatment. Induction hardening is a complex combination of electromagnetic, heat transfer, and metallurgical phenomena. On te other hand, induction hardening is an energy-efficient, in-line, heat-treatment process widely used in te automotive industry to surface-harden these kinds of parts at te lowest possible cost. Te substitution of induction heating/hardening for furnace heating/hardening can lead to savings of up to 95% of energy used in heat-treating operations, in addition to te energy savings enabled by optimization and lightweighting of automotive powertrain components.
Figure 1: Examples of automotive parts typically induction hardened, including axle shaft components, a steering rack, and miscellaneous pump shafts
Te traditional description of te steel hardening procedure involves heating te entire component, or a part of te component that needs to be hardened, to te austenitizing temperature, holding it if necessary for a period long enough to achieve complete transformation to austenite, and then rapidly cooling it below te martensite start (Ms) temperature, where martensite transformation begins.
Te three most common forms of induction hardening are surface hardening, through hardening, and selective hardening. Depending on te specific application, selective hardening is sometimes considered a part of surface hardening or through hardening. Induction hardening is accomplished by passing an alternating current through a water-cooled copper coil that is coupled to te part by te induced magnetic field. Te alternating magnetic field induces eddy currents that resistively heat te outer surface of te part.
For example, Figure 2 shows te dynamics of te induction heating of a carbon steel cylinder and its cooling during quenching for surface hardening. After 4.1 seconds of heating, te surface layer reaches a final temperature of approximately 1050°C (1920°F). Te core temperature does not rise significantly due to several factors, such as an electromagnetic skin effect and relatively short heating time. Because of these factors, te heat soak from te surface toward te core is not sufficient to equalize temperature along te radius.
Figure 2: Dynamics of induction heating of a carbon steel cylinder (20 mm OD) and its cooling during quenching (F = 40 kHz); red is heating and blue is cooling
After te heating stage is completed, te quenching stage begins. Te high temperature of te workpiece surface layer begins to decrease in te first stage of quenching. Figure 2 shows that after 2 seconds of quenching, te surface temperature is reduced by as much as 450°C (810°F), resulting in a workpiece surface temperature of 600°C (1110°F). At this point, te maximum temperature is located at a distance of 3 mm (0.120 in.) below te surface. After 5 seconds of quenching, te surface temperature decreases almost to te temperature of te quenchant, while te core still remains quite warm at a temperature above 400°C (750°F).
In some cases, heat treaters do not cool te part completely, and after unloading te part from te induction coil, it is kept for some time on te shop floor. During that time, te heat of te warm core travels toward te surface, eventually resulting in a uniform temperature distribution within te part. In this case, te remaining heat is used for a slight temper back (self-tempering), which imparts some ductility to te part.
Advantages of induction hardening:
Ability to localize hardening to specific areas.
Less distortion than alternatives such as carburizing.
Heavy case depths achievable, 1-10mm common.
Cheap/economical especially with parts of mass >10Kg.
Fast process - quick turnaround.
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