Induction hardening is a type of surface hardening in which a metal part is induction-heated and then quenched. The quenched metal undergoes a martensitic transformation, increasing the hardness and brittleness of the part. Induction hardening is used to selectively harden areas of a part or assembly without affecting the properties of the part as a whole.

Induction hardening is a useful method for improving resistance to surface indentation, fatigue and wear that is favoured in comparison with through hardening, which may lack necessary toughness. The process itself involves fast heating by induction with subsequent quenching, creating a martensitic layer at the surface of the workpiece. In the present work, we demonstrate how to simulate the process of induction hardening using a commercial finite element software package with focuses on validation of the electromagnetic and thermal parts, together with evolution of the microstructure. Experiments have been carried out using fifteen workpieces that have been heated using three different heating rates and five different peak temperatures resulting in different microstructures. It is found that the microstructure and hardening depth is affected by the heating rate and peak temperature. The agreement between the experimental and simulated results is good. Also, it is demonstrated that the critical equilibrium temperatures for phase transformation is important for good agreement between the simulated and experimental hardening depth. The developed simulation technique predicts the hardness and microstructure sufficiently well for design and the development of induction hardening processes.

Single shot hardening

In single shot systems the component is held statically or rotated in the coil and the whole area to be treated is heated simultaneously for a pre-set time followed by either a flood quench or a drop quench system. Single shot is often used in cases where no other method will achieve the desired result for example for flat face hardening of hammers, edge hardening complex shaped tools or the production of small gears.

In the case of shaft hardening a further advantage of the single shot methodology is the production time compared with progressive traverse hardening methods. In addition the ability to use coils which can create longitudinal current flow in the component rather than diametric flow can be an advantage with certain complex geometry.

Traverse hardening

In traverse hardening systems the work piece is passed through the induction coil progressively and a following quench spray or ring is used. Traverse hardening is used extensively in the production of shaft type components such as axle shafts, excavator bucket pins, steering components, power tool shafts and drive shafts. The component is fed through a ring type inductor which normally features a single turn. The width of the turn is dictated by the traverse speed, the available power and frequency of the generator. This creates a moving band of heat which when quenched creates the hardened surface layer. The quench ring can be either integral a following arrangement or a combination of both subject to the requirements of the application. By varying speed and power it is possible to create a shaft which is hardened along its whole length or just in specific areas and also to harden shafts with steps in diameter or splines. It is normal when hardening round shafts to rotate the part during the process to ensure any variations due to concentricity of the coil and the component are removed.