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Joining of Metals
Published in Sherif D. El Wakil, Processes and Design for Manufacturing, 2019
As the name suggests, induction welding is based on the phenomenon of induction. We know from physics (electricity and magnetism) that when an electric current flows in an inductor coil, another electric current is induced in any conductor that intersects with the magnetic flux. In induction welding, the source of heat is the resistance, at the abutting workpieces’ interface, to the flow of current induced in the workpieces through an external induction coil. Figure 4.16 illustrates the principles of induction welding. For efficient conversion of electrical energy into heat energy, high-frequency current is employed, and the process is usually referred to as high-frequency induction welding (HFIW). Frequencies in the range of 300 to 450 kHz are commonly used in industry, although frequencies as low as 10 kHz are also in use. It is always important to remember the “skin effect” when designing an induction-welded joint. This effect refers to the fact that the electric current flows superficially (i.e., near the surface). In fact, the depth of the layer through which the current flows is dependent mainly upon the frequency and the electromagnetic properties of the workpiece metal. Industrial applications of induction welding include butt welding of pipes and continuous-seam welding for the manufacture of seamed pipes.
Industrial Applications of Induction Heating
Published in Valery Rudnev, Don Loveless, Raymond L. Cook, Handbook of Induction Heating, 2017
Valery Rudnev, Don Loveless, Raymond L. Cook
Induction welding typically uses relatively high frequencies in the range of 200 to 600 kHz and power from 50 to 1500 kW [41]. Induction welding is usually a continuous operation. After welding, the seams are then subsequently annealed with a seam annealing system that follows the welding system in a continuous line.
Heating Systems
Published in Stephen W. Fardo, Dale R. Patrick, Electrical Power Systems Technology, 2020
Stephen W. Fardo, Dale R. Patrick
The induction welding process uses the principle of induction heating to fuse metals together. High-frequency AC is applied to a heating coil, into which the materials to be welded are placed. Tubular metal is often welded in this way.
Simulating the induction heating of cross-ply C/PEKK laminates – sensitivity and effect of material variability
Published in Advanced Composite Materials, 2021
Wouter J. B. Grouve, Francisco Sacchetti, Evan J. Vruggink, Remko Akkerman
Of the available welding technologies, induction welding is particularly attractive for carbon fiber reinforced thermoplastics as it does not require a susceptor material at the weld interface. The process relies on an alternating magnetic field to generate heat in the carbon fiber reinforced thermoplastic adherends in order to fuse them together [8–10]. The underlying heating mechanisms are Joule heating in the carbon fibers and in the fiber-fiber contacts, and dielectric heating at the fiber junctions [8,9,11–13]. Irrespective of the heating mechanism, induction heating requires the presence of eddy currents in the material [8,9]. Eddy currents are relatively easily generated in woven fabric composites, where the interlacement of bundles facilitates contact between perpendicular fibers to provide a conductive loop. This is not the case for composites based on unidirectional (UD) tape materials. The highly anisotropic nature of UD plies, which have a very low transverse electrical conductivity, hinders eddy current formation in a ply. Instead, the ability to form eddy currents in UD laminates depends on the through-thickness ply conductivity and the contact resistance at the interfaces between plies with different fiber orientations [14,15].