The Influence of “Lightweighting” on Induction Heat Treatment Processes

Due to the complexity of the electromagnetic, thermal, and metallurgical phenomena inherent to induction heat treating, computer simulation is a powerful tool in the design of induction heat treating equipment and processes.  In the aerospace and automotive industries, in which aggressive weight reduction, or “lightweighting”, is pursued on a component-level, the ability to precisely simulate and evaluate the feasibility of induction heat treatment processes is extremely valuable.  In the many cases in which material substitution (e.g. replacing steel with aluminum or titanium) is not feasible due to mechanical requirements and/or economic considerations, weight reduction is often achieved by deliberate and calculated removal of material is localized regions of the component (based upon its loading conditions in operation).  While this approach can provide valuable reductions in component weight, the geometric complexity of the component – and therefore the intricacy of associated induction heat treatment processes – is often increased dramatically.  Utilizing 2D and 3D computer simulation and a number of real-world case studies, this presentation illustrates a number of subtle electromagnetic and thermal challenges created by common geometric complexities and provides practical induction heat treatment solutions for addressing these challenges.