Abstract
Thermal fatigue represents a primary failure mode in induction heating coils used for induction hardening processes. While previous literature has identified several contributing factors—including radiation from part surfaces, frequency, current, concentrator losses, water pressure, and coil wall thickness—quantitative data regarding their relative impact remains scarce in publicly available resources. This study employs finite element analysis software to systematically evaluate and quantify the influence of common inductor cooling design variables on thermal fatigue development. Our research methodology centers on a comprehensive case study utilizing a single-shot induction coil with Fluxtrol A concentrator, providing a controlled environment for precise analysis. This approach establishes a quantitative hierarchy of design factors affecting thermal fatigue, offering evidence-based guidance for optimizing induction coil design and extending operational lifespan in industrial applications.
