Mend Tech Inc. is a small company that values transparent communication, long-term partnerships, and fast turnaround times for our services without compromising on quality and
precision. Additionally, we bring together decades of industry expertise and real-world experience to deliver high end solutions, power supplies, coils, and repairs, treating each job uniquely and
carefully with confidence backed by knowledge.
Induction heating is a process that uses electromagnetic fields to heat conductive materials. An electromagnetic field is generated by passing alternating current (AC)
through a coil. When a metal workpiece is placed within this field, eddy currents are induced and generate heat into the material.
Unlike other heating methods, induction transfers energy directly into the part being heated without physical contact. This results in faster, cleaner, better
controlled heating, making it a great solution for a wide range of industrial applications.
Energy Efficiency
Reduce energy consumption by focusing heat only where it’s needed, eliminating wasted heat.
Precision & Control
Induction allows for the ability to control heating patterns.
Increased Production Volume
Rapid heating reduces cycle time and increases production.
Safety & Cleanliness
No flame or combustion creates a safer environment. Induction is a clean and environmentally friendly solution.
Reduce Maintenance
Induction systems have minimal moving parts and contact wear. This reduces equipment maintenance and extends the system’s lifespan.
Examples:
Automotive & Transportation
- Hardening and tempering gears, shafts, and bearings
- Brazing fuel lines and air-conditioning components
Aerospace & Defense
- Heat treating turbine blades and landing gear components
- Pre-heating and post-weld heating of critical structures
Metalworking & Manufacturing
- Forging and billet heating
- Annealing, stress relieving, and weld post-heating
Oil & Gas
- Pipe coating and preheating
- Pipeline stress relieving and weld post-heating
Medical & Pharmaceutical
- Precision heating or implant manufacturing
- Sterilization of surgical tools
Renewable Energy
- Bonding solar panels and wind turbine components
- Heating for battery technology
An induction power supply generates the alternating current required to create a rapidly changing electromagnetic field, which induces heat in a conductive
material.
- The induction power supply takes an alternating current and converts it to high frequency alternating current through a rectifier that converts the incoming AC to
DC.
- The DC converted is then passed through an inverter, which switches the DC back into high frequency AC.
- The high frequency AC flows through a copper induction coil, generating a rapidly changing magnetic field around the coil. When conductive material is placed inside
or near the coil, the magnetic field induces eddy currents within the part.
- The induced eddy currents flow through the workpiece, encountering resistance within the material. The amount of heat generated will depend on the power and frequency
of the power supply, properties of the material, and coil design.
Induction coil geometry plays a critical role in determining the efficiency, heating pattern, and effectiveness o the indction heating process. The shape and design of the coil are customized
based on the part's size, shape, and heating requirements. Below is an overview of the most common coil geometries:
1. Single-Turn (Solenoid) Coil
Design: A simple, single-loop coil that surrounds the workpiece.
Applications: Ideal for heating cylindrical parts such as rods, tubes, and shafts. Used for surface hardening, annealing, and brazing.
Advantages: Provides uniform heating along the surface. Simple and cost-effective to manufacture.
2. Multi-Turn (Helical) Coil
Design: A helical coil with multiple turns wound around the workpiece.
Applications: Suitable for heating longer or irregularly shaped workpieces. Commonly used for billet heating, tempering, and forging.
Advantages: Provides deeper and more uniform heating. Increases heating efficiency by maximizing electromagnetic coupling.
3. Pancake (Flat Spiral) Coil
Design: A flat, spiral-shaped coil where the turns lie in a single plane.
Applications: Ideal for heating flat or disc-shaped components. Frequently used for surface hardening, bonding, and brazing of flat surfaces.
Advantages: Delivers precise and localized heating. Ensures efficient heat distribution on flat surfaces.
4. Channel Coil (Internal or External)
Design: A coil shaped like a channel or groove, where the workpiece fits either inside or around the coil.
Applications: Used for heating strips, wires, and small cylindrical parts. Often applied in induction brazing and heat-treating processes.
Advantages: Enables focused heating with minimal heat loss. Suitable for narrow or elongated parts.
5. Hairpin (U-Shaped) Coil
Design: A U-shaped coil with two parallel legs surrounding the workpiece.
Applications: Commonly used for selective heating of specific areas. Ideal for brazing or hardening specific zones on small components.
Advantages: Provides localized heating to targeted areas. Allows for flexible positioning and heating control.
6. Split-Return (C-Shape) Coil
Design: A split coil that partially surrounds the workpiece, allowing easy loading and unloading.
Applications: Suitable for heating large parts or parts with complex geometries. Often used in applications where full coil enclosure is not feasible.
Advantages: Easier handling and loading of parts. Effective for heating irregular shapes.
7. Conformal (Custom-Fit) Coil
Design: A custom-designed coil that closely follows the contour of the part.
Applications: Used for complex or unique shapes that require consistent heating.
Ideal for aerospace and specialized automotive components.
Advantages: Delivers uniform heating to irregular parts. Reduces heating time and increases process accuracy.
8. Ferrite Core Coil
Design: A coil with a ferrite core to concentrate the magnetic field.
Applications: Used for localized heating and brazing of small components. Often applied in situations where precise heat control is required.
Advantages: Enhances magnetic flux density. Minimizes heat loss and increases efficiency.