Does 3D-Printed Coil Perform Better for Induction Hardening and How to Predict the Performance Based on Numerical Simulation?

Recent developments in additive manufacturing (also called 3D printing of inductors) have opened new possibilities in the induction heating field by making inductors that have a longer service life and are more reproducible. Computer simulations were done to compare inductors made with two different techniques – conventional manufacturing and additive manufacturing. To compare inductor performance, heating of the soldered joints, the change in power consumption in the inductors and the temperature field in the workpiece were studied. Also, different steel structures such as austenite, bainite, pearlite, and martensite were studied to measure the case depth of the workpiece. All calculations were done by using CENOS simulation software, which uses a coupled electromagnetic-thermal model to describe the induction heating process. For the phase transition calculations a time-temperature transformation diagram was used.