This presentation will discuss the most common types of induction tooling failures and the best practices to improve the performance and longevity of inductor coils, bus bars quenches and related tooling. We will discuss the harsh environment of a typical induction machine installation and what can be done to reduce contamination, which is the leading cause of tooling failure. Robust tooling designs and how water cooling is essential to longevity shall be discussed. Cooling water temperature and how the water is presented and routed through the tooling components and the impact this has on performance and longevity shall be discussed. We will discuss the use of proper materials, fittings and hoses which are often overlooked and can be detrimental to a process if not correctly selected. We will cover the induction machine and how it is essential to have a proper earth ground and the importance of proper machine fixturing and alignment. We shall discuss the importance of scheduled machine maintenance, scheduled service and calibration. The presentation will summarize the most common types of failures, how maintenance is essential for longevity and the importance of high-quality robust tooling.

This presentation will discuss the most common types of induction tooling failures and the best practices to improve the performance and longevity of inductor coils, bus bars quenches and related tooling. We will discuss the harsh environment of a typical induction machine installation and what can be done to reduce contamination, which is the leading cause of tooling failure. Robust tooling designs and how water cooling is essential to longevity shall be discussed. Cooling water temperature and how the water is presented and routed through the tooling components and the impact this has on performance and longevity shall be discussed. We will discuss the use of proper materials, fittings and hoses which are often overlooked and can be detrimental to a process if not correctly selected. We will cover the induction machine and how it is essential to have a proper earth ground and the importance of proper machine fixturing and alignment. We shall discuss the importance of scheduled machine maintenance, scheduled service and calibration. The presentation will summarize the most common types of failures, how maintenance is essential for longevity and the importance of high-quality robust tooling.

Although great strides are being made in the simulation of induction patterns, most of today’s inductor design and validation activities are still done through experience and experimentation. This paper provides a brief overview of how an inductor is designed, fabricated, and prepared for integration into manufacturing. Each aspect of its manufacture is critical to deliver a hardening inductor capable of meeting engineering drawing requirements and to be ready for production. The paper covers determination of requirements, inductor design, fabrication and assembly, process development, inductor characterization, metallurgical validation, and delivery of a production-ready inductor. Each step is described, and important considerations for each are presented.