Efficient Induction Welding Solutions

As a leading manufacturer in China, we provide high-performance induction welding machines and power supplies for diverse industries. Our solutions, both custom and ready-made, ensure exceptional quality and reliability, meeting the highest industry standards.

    KEXIN Induction Welding Machines

    Induction welding is vital for achieving optimal metal properties. At KEXIN, we offer advanced solutions with durable systems and precise results using third-generation inverter technology and IGBT heating elements.

    We customize systems for specific heating needs and integrate automation to boost efficiency and consistency. KEXIN sets the standard for innovative and reliable induction welding.

    WHAT IS INDUCTION WELDING

    What is Induction Welding?

    Induction welding uses electromagnetic induction to heat workpieces. It is ideal for long production runs and highly automated processes, commonly used for welding pipe seams. The process transfers intense power to localized areas, melting surfaces quickly. Pressing these surfaces together forms a continuous, rolling weld.

    During the process, workpieces are heated below their melting point. Edges are aligned and impurities are expelled, creating a solid forge weld.

    Induction welding joins thermoplastics and thermosetting composites. Essential equipment includes a radio-frequency generator, heating station, workpiece material, and cooling system.

    The Basics of Induction welding:

    Induction welding is a process that uses electromagnetic induction to heat materials. It involves an induction coil energized by a radio-frequency electric current. This creates a high-frequency electromagnetic field that heats the workpiece.

    The difference between induction welding and other welds

    Induction welding is an automated process suitable for long production runs, such as pipe seam welding. It uses electromagnetic fields to heat localized areas rapidly. Metal surfaces melt quickly and compress to form strong welds. Penetration depth depends on the metal’s composition and temperature. Unlike resistance welding, induction welding does not require physical contact. Current is induced in the workpiece through electromagnetic fields. This reduces equipment wear and contamination risks. It also ensures faster and cleaner operations compared to other welding methods.

    THE INDUCTION WELDING PROCESS

    What is the Induction Welding Process?

    Heating Mechanism

    Heating occurs through two main effects: resistive heating and hysteresis heating. In conductive materials, eddy currents are induced by the electromagnetic field, generating heat. In ferromagnetic materials, the realignment of magnetic domains within the material creates additional heat. Most workpieces experience a combination of these two effects, allowing for uniform and controlled heating.

    Joining the Workpieces

    The heated workpieces are brought to a temperature below their melting point. At this stage, their edges are aligned and pressed together under controlled pressure. This process expels impurities from the weld area, preparing the surfaces for a solid bond.

    Forge Weld Formation

    Once the impurities are removed, the combination of heat and pressure creates a strong, uniform weld. This solid forge weld is durable and consistent, ensuring reliable performance for industrial applications.

    The Benefits Of Induction Welding

    Energy Efficiency

    Induction welding uses three-phase power and consumes less energy. It eliminates the need for gas combustion, reducing energy costs and environmental impact.

    Superior Heating Effect

    Induction welding provides uniform and consistent heat through magnetic fields. This ensures fully melted solder and creates stronger, more reliable welds.

    Eco-Friendly Solution

    Unlike gas welding, induction welding produces no smoke or waste. It is a cleaner and more sustainable option for industrial processes.

    Cost-Effectiveness

    While the initial investment is higher, induction welding is more cost-effective for large-scale production. It delivers high-quality welds with lower operational costs over time.

    Ease of Operation

    Induction welding does not rely on operator skill. Its automated controls reduce the risk of errors and ensure predictable results.

    Induction Welding For Diverse Applications

    Induction Welding for Steel Molds

    Induction Welding for Steel Molds

    Induction Welding for Stainless Steel Tubes

    Induction Welding for Stainless Steel Tubes

    Induction Welding for Medical instruments

    Induction Welding for Medical instruments

    Induction Welding for Dispenser Copper Pipes

    Induction Welding for Dispenser Copper Pipes

    Induction Welding for Wrench Tools

    Induction Welding for Wrench Tools

    Induction Welding for Large Metal Components

    Induction Welding for Large Metal Components

    Induction Welding for Large Metal Components
    Induction Welding for Large Metal Components

    Some Typical Materials Used For Induction Welding

    • Steel
    • Aluminum
    • Copper
    • Brass
    • Titanium
    • Nickel alloys
    • Stainless steel
    • Carbon fiber composites

    Industries Of Induction Welding

    Induction welding is a fast and efficient method of joining metals without the need for external pressure or filler material. This process is widely used in various industries to create strong and durable welds. It is widely used in various industries:

    Electrical Industry

    Electrical Industry

    Induction welding is used in the electrical industry for joining components like copper wires, busbars, and electrical connectors. The high precision and efficiency of induction welding make it a preferred method for producing reliable electrical connections.

    Construction Industry

    Construction Industry

    In the construction industry, induction welding is used for joining pipes, tubes, and other structural components. This method ensures leak-proof and strong welds, making it essential for applications in plumbing, HVAC systems, and structural steel fabrication.

    Medical Industry

    Medical Industry

    Induction welding is also used in the medical industry for joining medical devices and equipment. The precise control and cleanliness of the welding process make it a preferred choice for manufacturing critical medical components.

    FAQS

    01.What is an induction welding?

    Induction welding is a type of welding that fuses two or more metals together using the resistive heat caused by changing electromagnetic fields, otherwise known as induction. During induction welding, a work piece is surrounded by conductive coils. The changing magnetic field is typically induced through the use of an alternating current that runs through the conductive coils.

    02.Why should I buy an induction welding machine?

    Induction welding machines are used because they offer efficiency, fast heating, safety, cleanness, and accurate control. They are the fastest method for hardening and heat treating, resulting in minimal distortion and a fine-grain microstructure. Induction heating is accurate, fast, repeatable, and efficient, making it suitable for precise or repetitive operations. It is a rapid, energy-efficient, flameless method of heating electrically conductive materials.

    03.What are the advantages of induction welding machine?

    High efficiency and energy saving.  It can save 2/3 of the power than the high frequency of the electron tube.

    Low maintenance costs. No fragile and expensive tubes.

    Special Safety: No high voltage, eliminating the danger of high voltage electric shock.

    Easy to Install: Just connect the power supply and water pipes; it can be completed in 10 minutes.

    Easy operation: user can learn in a few minutes.

    04.How to choose the frequency of induction welding machine?

    For different workpiece materials, sizes and shapes, the frequency will be different accordingly.

    Please send inquiry to us, we will recommend the optimal induction heating machine on your request.

    05.How to choose the cooling system for induction welding machine?

    We will recommend the most suitable cooling system based on different heating requirements.

    06.Do I need to buy a cooling system separately for KEXIN induction welding machine?

    Yes, you can prepare a water tank and a water pump to work as cooling system; Or you can directly prepare a cooling chiller.

    07.Can induction welding be used for pipe seam welding?

    Yes, it is commonly used for welding the seams of pipes.

    08.What equipment is required for induction welding?

    A radio-frequency power generator, heating station, workpiece material, and cooling system are essential components.

    09.How does induction welding compare to resistance welding?

    Induction welding uses electromagnetic fields without direct contact, while resistance welding applies current through contacts.

    10. What is the typical frequency range used in induction welding?

    High-frequency currents are commonly used, but specific frequencies depend on the application.

    11. What maintenance is required for induction welding equipment?

    Regular inspection, cleaning, and calibration are necessary to maintain performance.

    12. What are the cost considerations for implementing induction welding?

    Initial equipment costs may be higher, but operational efficiency can lead to long-term savings.

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