Induction Welding in Sheet Metal Manufacturing

Induction welding is a high-frequency welding technique that involves the use of an electromagnetic frequency to generate heat and excite an implant at the joint of two or more parts to be welded. The process involves an electromagnet and radio frequency that powers/heat an induction coil. The heated coil generates melts on the material surfaces and fuses with the implant surrounding the parts to be joined.

The implant used in induction welding is usually a composite material, consisting of the polymer to be welded along with ferromagnetic particles or metal fibres. Induction welding is a very reliable and high-speed welding technique. Unlike other welding techniques, induction welding doesn’t depend much on the properties of the parts to be welded; this, therefore contributes to its diversity, making is suitable for thermoplastics, metals and high-performance resins.

Benefits of Induction Welding

1.     Automation

Induction welding may be considered semi-automated due to some aspect of the process. Load matching is one of such functions to ensure that the right amount of heat and power is automatically supplied to match the welding requirements of the parts.

2.     Efficiency

Induction welding is one of the most reliable welding techniques. This is because it provided tight welds that are almost infallible. The welding process uses less electricity relative to other high-frequency welding techniques, and delivers more productivity for large-scale welding.

Induction welding also eliminates the chances of equipment failure that may be caused by open circuiting in contact welding. It eliminates the downtimes caused by electrode replacement as it used a no-contact electrode consumption.

3.     Precision

Induction welding can produce focused heat that allows for specific joining of materials without damaging or affecting other areas of the workpiece. This is what makes induction welding particularly attractive for plumbing pipes and fittings.

4.     Quality

Induction welding provides fabricators with structurally-sound and pressure-tight welding that are sure to stand the test of time. Its diversity also means that it can be used for stress-free thermoplastic welding.

The implant used in the welding improves the polymer-to-polymer and part-to-part linkage. It is also excellent in welding parts with surface irregularities, parts that have been molded, thermoformed and those with the most complex geometries. The welding process is stable and less stringent on strip joints and surface quality and welding adjustment is easy and seamless.

5.     Eliminates impurities

The high-frequency electromagnetic waves involved in the induction welding process is capable of forcing out impurities from the individual workpieces to be welded. This is because as the individual parts are heated, the impure compounds seep out of them at elevated temperature. Because of this, induction welding makes higher-quality welds with cleaner workpieces

6.     Speed

The heating speed of induction welding is fast, allowing the workpiece to get to the desired temperature quicker. The induction welding device also needs no warm up, and although contact welding may be faster, the overall cycle time is lower for induction welding due to the efficiency of the process.

7.     Range

Induction welding can be used for a diverse range of materials. From iron to thermoplastic, high-quality resins, plastic, composites, metal and steel, induction welding can be used to bring a number of materials together. Both ferrous and non-ferrous materials can be joined. The implant technique in injection welding also means that plastic materials can be brought with other ferrous compounds.

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