This paper investigates the effect of various types of errors on the accuracy of finite-element models used to simulate electromagnetic induction heat treating processes. By comparing simulation outputs, it shows how FEA calculations are affected by incorrect material specifications, incorrectly entered data, imprecise data, misassigned elements, unsuitable mesh sizing, inadequate current or power, and failure to properly account for skin effect depth. The paper includes relevant data and equations in addition to computer generated plots.

Inductive welding systems used to make metal tubes often incorporate a ferrite impeder to limit induced electrical current on the ID of the tube under the induction coil. This paper assesses the improvement that can be achieved through the use of soft magnetic composites, instead of ferrite, and the addition of an external magnetic controller or bridge. The authors explain how they simulated the potential impact of the two design modifications and experimentally verified the results.