ASM Handbook Volume 4C : Induction Heating and Heat Treatment

This ALL NEW ASM Handbook gives design, manufacturing, and material engineers a practical and comprehensive reference on the technologies and applications of induction heating and heat treatment. This book provides practitioners, students, engineers, and scientists the knowledge to more clearly understand and obtain solutions for typical induction heating problems that they encounter on an everyday basis.

Continuing in the tradition of the ASM Handbook series, this Volume provides a unique combination of practical knowledge grasping ready-to-use diagrams, technical procedures, guidelines, and good practices with advanced theoretical knowledge emphasizing on specifics of induction processes compared to alternative technologies. An appreciable amount of material is devoted to practical aspects, including review of standard and customized induction equipment. Special attention is paid to describing quality assurance, process monitoring, maintenance and safety procedures, energy and environmental aspects, including control of magnetic field exposure and review of international standards and regulations.

Written by internationally recognized experts, ASM Handbook Volume 4C covers the breadth and significance of induction heating and heat-treatment technologies and applications. See the sample chapter and the Table of Contents for more information. Beginning with reviewing electrical, electromagnetic, heat transfer and material science fundamentals related to induction heating, along with coverage critical facets associated with this technology such as:

• Nonequilibrium nature of phase transformation and other metallurgical subtleties related to the specifics of induction hardening, tempering, stress relieving, heating prior to hot working and melting.
• Review of ASTM and SAE standards and guidelines in proper measuring of hardness case depth and heat affected zone. Pattern specification as well as issues and complications related to different hardness measuring techniques. Destructive and nondestructive testing.
• Selection of critical process parameters and inductor styles, heat pattern control, the use of magnetic flux concentrators, quench design subtleties as well as a review and explanation of common misconceptions and erroneous assumptions.
• Formation of residual and transient stresses and their impact on a performance of heat treated components.
• Temperature requirements for heating carbon steels, alloy steels, super alloys, titanium, aluminum and copper alloys and other materials prior to hot and warm working. Novel technological developments in heating billets, bars, tubes, rods and other metallic workpieces.
• Optimization procedures and strategies in obtaining optimal process control algorithms based on various technological criteria, real-life constrains and cost functions (e.g., maximizing throughput and temperature uniformity, energy effectiveness, minimizing required shop floor space and metal loss, etc.). Principles of multiobjective optimization of induction heating devices.
• Induction hardening of critical components, including gears, axle shafts, camshafts, crankshafts, and other components used in automotive and off-road machinery, aeronautic and aerospace engineering, farming, appliance, oil and gas industries.
• Failure analysis of induction heat treated components and comprehensive review of defects and abnormal characteristics.
• Good practices in designing and fabricating long-lasting induction coils and ways to avoid their premature failures.
• Special applications of electromagnetic induction, including melting glasses and oxides, optical fiber draw, nanoparticle heating and hyperthermia applications.
• Design principles and operation specifics of transistorized and thyristorized power supplies for induction heating needs.
• Modern computer modeling and specifics of simulation of induction thermal processes.

Foreword
Preface
Policy on Units of Measure
List of Contributors and Reviewers

Section I : Fundamentals
Chapter 1 : History and Applications
Chapter 2 : Principles of Induction Heating
Chapter 3 : Electromagnetic and Thermal Properties of Materials
Chapter 4 : Estimation of the Basic Induction Process Parameters

Section II : Induction Heat Treating
Chapter 5 : Metallurgy of Induction Hardening of Steel
Chapter 6 : Principles of Induction Hardening and Inspection
Chapter 7 : Quenching of Induction Heated Steel
Chapter 8 : Residual Stresses in Induction Hardened Steels
Chapter 9 : Tempering of Induction Hardened Steels
Chapter 10 : Induction Case Hardening of Axle Shafts
Chapter 11 : Induction Hardening of Crankshafts and Camshafts
Chapter 12 : Induction Hardening of Gears and Gear-Like Components
Chapter 13 : Induction Hardening Off-Road Machinery Components
Chapter 14 : Induction Hardening for the Aeronautic and Aerospace Industry
Chapter 15 : Defects and Abnormal Characteristics of Induction Hardened Components

Section III : Modeling & Simulation of Induction Heat Treating
Chapter 16 : Methods, Tools, and Software for Physical Process Analysis and Design
Chapter 17 : Electromagnetic Problem Solutions
Chapter 18 : Thermal Problem Solutions
Chapter 19 : Coupled Problem Solution
Chapter 20 : Modeling and Simulation of Stresses and Distortion in Induction Hardened Steels

Section IV : Induction Heating
Chapter 21 : Warm and Hot Working Applications
Chapter 22 : Carbon Steels and Alloy Steels Used in Warm and Hot Working
Chapter 23 : Temperature Requirements for Heating Super Alloys and Stainless Steels
Chapter 24 : Temperature Requirements for Heating Titanium, Aluminum, Magnesium, and Copper Alloys
Chapter 25 : Induction Heating of Billets, Rods, and Bars
Chapter 26 : Induction Heating of Selective Regions
Chapter 27 : Basic Principles of Optimal Design of Electromagnetic Devices and Multi-objective Optimization
Chapter 28 : Optimal Control of Induction Heating of Metals Prior to Warm and Hot Forming

Section V : Induction Melting
Chapter 29 : Introduction and Fundamental Principles of Induction Melting
Chapter 30 : Computational Modeling of Induction Melting and Experimental Verification
Chapter 31 : Components and Design of Induction Crucible Furnaces
Chapter 32 : Components, Design, and Operation of Vacuum Induction Crucible Furnaces
Chapter 33 : Components and Design of Channel Inductor Furnaces Furnace Vessel
Chapter 34 : Metallurgy of Induction Melting Processes for Iron and Non-Iron Materials
Chapter 35 : Operation of Induction Furnaces in Iron Foundries
Chapter 36 : Operation of Induction Furnaces for Steel and Non-iron Materials
Chapter 37 : Melting of Glasses and Oxides
Chapter 38 : Energy and Environmental Aspects of Induction Melting Processes
Chapter 39 : Operating Safety of Induction Melting Furnaces

Section VI : Equipment
Chapter 40 : Fundamentals and General Aspects of Power Supply Design for Induction Heating, Heat Treating, Welding, and Melting
Chapter 41 : Power Supplies for Induction Heat Treating, Brazing, and Soldering
Chapter 42 : Design and Fabrication of Inductors for Induction Heat Treating
Chapter 43 : Design and Fabrication of Induction Coils for Heating Bars, Billets, and Slabs
Chapter 44 : Design and Fabrication of Inductors for Heat Treating, Brazing, and Soldering
Chapter 45 : Magnetic Flux Controllers in Induction Heating and Melting
Chapter 46 : Systematic Analysis of Induction Coil Failures and Prevention
Chapter 47 : Transformer Design and Load Matching
Chapter 48 : Vertical Scanners, Horizontal Scanners, and Tooth by Tooth Scanners
Chapter 49 : Controlled Atmosphere Chambers
Chapter 50 : Material Handling Equipment for Induction Heating Systems
Chapter 51 : Maintenance of Induction Heat Treating Equipment
Chapter 52 : Water Cooling for Induction Systems

Section VII : Process Control, Monitoring, Design and Quality Assurance
Chapter 53 : Process Control, Monitoring and Quality Insurance Specifics for Induction Heating
Chapter 54 : Using Infrared Thermometers to Control Temperature During Induction Heating
Chapter 55 : Induction Heating Control System
Chapter 56 : Process Design for Induction Brazing and Soldering
Chapter 57 : Inspection and NDT Methods
Chapter 58 : Control of Professional Magnetic Field Exposure-International Standards and Regulations

Section VIII : Special Applications of Induction Heating
Chapter 59 : Historical Review of Induction Glass Melting
Chapter 60 : Induction Glass Melting and Forming
Chapter 61 : Induction Heating in Optical Fiber Draw Processing
Chapter 62 : Nanoparticle Heating Using Induction in Hyperthermia

Index