Induction Forging & Hot Forming Applications
Forging technology can range from prehistoric to space age. The latest improvements in induction forging offer precision, speed, and safety. Let’s see how you can use them to your advantage!
The Key Advantages of Induction Forging
- Rapid: Much faster net heating time – induction can take heating prior to forging from a high of 5-6 minutes/part to 10-50 seconds/part (depending on the part diameter) and still achieve the required core target temperatures.
- Flameless and Safe: No open flames, no reliance on Oxy Acetylene torches, and no need for storing flammable gas tanks. No ordering more gas cylinders month after month.
- Consistency and Repeatability: Our Master Controller V3+ controls for power, time, and/or temperature. Save your preferred settings and then retrieve them later when you’re running that specific workpiece again, ensuring consistent and even heating for each application.
- Energy-Efficient: Power-on-Demand induction heating saves both energy and time. Our highly-efficient generators have a power factor > .96. They also offer the option of continuous operation or cycling on/off between each part for even more energy efficiency.
- Localized Heating for Precision: Heat can be applied only where needed.
- Automatable for Enhanced Productivity: Can integrate with automated heating processes, driving cost-effective, high-volume production
Introducing Semi- and Fully-Automated Induction Forging Systems
Seeking to improve efficiency and precision? Our induction heating technology are ready out-of-the-box to be integrated in automated hot forging systems. These systems optimize performance for industries requiring reliable and consistent heating while drastically reducing manual intervention.
Our customers have used our automation solutions to streamline manufacturing for aerospace and outer space applications, construction, and various other hot-forming applications.
See the video to experience how using induction heating in automated hot forging systems drives performance and innovation in forging and hot forming applications.
Why Inductronix for Induction Forging and Hot Forming?
Our systems can do more than just heat. They can also validate temperature accuracy using dual-color optical pyrometers that can verify that each part reaches its precise target temperature, eliminating guesswork and enhancing reliability.
Key operational settings—power, time, and temperature—are securely stored in our Master Controller, which offers graphical real-time thermal profile management and monitoring for optimized process control.
Additionally, all settings and temperature readings are logged in our real-time Data Logger, accessible from the front-end panel and are downloadable in .csv format to assist with QA tracking and auditing.
Thermal Profile Management and Monitoring:
- Program up to 20 temperature and time segments per process.
- Store up to 100 unique processes for future use
- Customizable maximum power output for each segment
- Programmable temperature tolerance windows to ensure consistent quality
- End-of-cycle alerts for each process
- Integrated web server and true data logging system
- Remote field-bus option available
Our advanced Thermal Profile Monitoring software, combined with SH15/SLE Optical Pyrometers, enables users to define precise temperature profiles, closely monitor heating progress, and certify each production item's quality. A real-time thermal profile display and an integrated web server further simplify status monitoring, remote programming, and data logging. With a built-in Ethernet switch and zero configuration networking, the system offers connectivity and streamlined operation.
By integrating advanced thermal verification and data management, our systems can deliver precision, consistency, and efficiency every time.
Case Study – Flame Torch Forging to Semi-Automated Induction Forging
We have an aerospace/commercial customer who was using a flame torch to heat billets, at 5-6 minutes per billet. Only a few operators had the skill to heat the billets, and even so, the results were inconsistent. Some parts had a core temperature too cold for the final forging process, and some were so hot that they turned gummy, and material was lost.
We introduced a semi-automated induction forging solution. They went from heating just one billet to heating multiple billets simultaneously in under 1 minute.
Operators call up pre-saved profiles that use our real-time temperature and power control, ensuring that billets reach their core target temperature each and every time.
How do they know the core target temperature is being reached every time? Our real-time monitor and data logger tell them, providing continuous feedback and enabling management to download logged results for QA and auditing.
Results
- Production output increased well over 500%
- Passed audit by their major customer
- Over 30% reduction in waste material
- Safer plant environment with no Oxy Acetylene storage
- Safer operations overall
This transformation optimized their workflow, elevated quality assurance, and delivered measurable improvements in efficiency and safety.
Thermal Profile Management and Monitoring
- Up to 20 Programmable Temperature and Time Segments per Process
- Up to 100 different storable processes
- Maximum Power Output Programmable for Each Individual Segment
- Temperature Tolerance Window Programmable for Each Individual Segment
- Out-of Tolerance and End-of-Cycle Outputs for Each Process
Thanks to the Thermal Profile Monitoring software, coupled with the new SH15/SLE Optical Pyrometers, the user is now able to set specific temperature profiles, and monitor and certify the heating process of each production item.
Real-time Thermal Profile Screen, combined with Web server and Data Log option
Integrated Web Server and Data Log System
- Integrated Webserver with 2-port 100base-T Ethernet switch
- No client software required, only a web browser
- Zero configuration network for simple setup
- Built-in Rich Internet Application (RIA) for Status Monitoring, Remote Programming, Logging and Thermal Profile Management
- Internal storage capacity for more than 100,000,000 data samples
Data Logger Screen
New Add-On Feature Available
In addition, we also have a new add-on feature called Thermal Profile, where you can see a temperature/power graph on-the-fly as you’re heating the wire. You can see any temperature variations in real-time.
The very fast response time of the Integrated Controller (=0.5 ms) allows for very precise and sharp temperature control.
About Induction Technology Solutions Inc.
Headquartered in Anaheim California, Inductronix offers complete induction solutions for various industries throughout North America. We have a combined 120 years of experience in various types of application requirements.
We offer a variety of Induction Heating Power Supplies and systems of all Output Power and Frequency ranges, Cooling Systems, Induction Heating coils, and now automation, to accommodate your specific heating requirement. We also can provide engineering support, such as evaluating a sample of your product that needs to be heated to help you determine the best and most cost-effective solution for your production requirement.
Try our free calculator
Check out our Induction Heating Calculator for running basic calculations to help you size your induction heating applications.
Why choose induction technology solutions?
Free Application Testing & Demos Available
Large In-Stock Inventory for Fast Lead Times
Lower Cost & Increase Productivity with Automation
Personable Customer Service
Our experts are ready to help!
Call one of our Engineering Information Specialists
