Applications Technology

In recent years Inductotherm Heating & Welding Ltd has established itself to be a worldwide Induction Heating & Welding solutions provider. The company’s Applications Support Engineers are equipped with specialist software enabling them to conduct real time process simulation in order to assist prospective customers with feasibility studies.

The benefits to a potential customer are considerable. Initial results can make all the difference when looking at return on investment as both energy efficiency and production rates can be predicted.

For prospective customers with Tube and Pipe Welding applications, custom software has also been developed to specify the correct weld power for a given product table. The Thermatool Weld-Rate Calculator will calculate both weld power and/or mill speeds that can be achieved for a range of tube diameters and wall thickness. Similarly, the Thermatool Annealer Calculator will predict required cooling distances and calculate the Seam or Full Body heating power required.

The following examples illustrate what Inductotherm Heating & Welding are able to provide prospective customers in the form of pre-sales applications engineering and technical support.

Thermal Simulation of Billet Heating

The following parameters can be simulated for a specific billet heating application:-

•   Energy Efficiency
•   Thermal Mapping
•   Verification of Production Rates

Please click on the pdf below for more information concerning this application

Thermal Simulation of the Induction Heating of 80 inch diameter Line Pipe

The following parameters can be simulated:-

•   Temperature Distribution with Time
•   Verification of Production Rates
•   Temperature Homogeneity

Please click on the pdf below for more information concerning this application

Calculation of Weld Power (kW) or Mill Speed (MPM)

The Thermatool Weld-Rate Calculator will basically determine how many kilowatts of HF weld power are required to produce tube of a specific diameter and wall thickness, at the required mill speed.

Conversely, it can be used to calculate those mill speeds that can be achieved by using a Thermatool CFI 250kW welder. In both cases, the calculations assume that optimum weld conditions exist. i.e. correctly specified work coil and impedor, correct strip edge presentation, correct squeeze roll configuration, correct vee angle, correct vee length etc.

The example below illustrates that 206kW of weld power is required to successfully weld 156mm diameter/ 6mm wall tube (from carbon steel strip) at a mill speed of 25 m/min, with no internal scarfing.