While the induction heating of non-ferrous alloys is fundamentally no different than that of other metals, the unique physical properties of different non-ferrous alloys have a number of critical induction heating implications. This paper addresses a number of physical characteristics and practical subtleties associated with the induction heating of non-ferrous alloys, focusing particularly on the influence of electromagnetic and thermal material properties. A mathematical optimization routine for continuous induction heating processes is also presented. Utilizing coupled electromagnetic-thermal FEA computer simulation results and taking into account real-world process requirements, this routine is used to maximize induction heating quality and equipment performance.

This paper will address practical aspects of developing induction heat treatment processes – induction hardening processes in particular. Examples will be presented to illustrate methods of improving inductor and process designs utilizing computer simulation. A number of everyday challenges encountered by heat treatment practitioners will be addressed, specifically challenges related to metallurgical and mechanical quality. The value of utilizing computer simulation will be demonstrated in these real-world solutions through the revelation of subtle facets of induction heat treatment that cannot otherwise be physically observed or measured.