Induction in Automotive Manufacturing

How is induction heating used in automotive manufacturing?

For decades, Ambrell has been partnering with the world’s largest automotive OEMs, integrators and Tier 1 and 2 suppliers to deliver superior induction heating solutions.

Induction generates an electromagnetic field in a work coil that induces currents in the conductive material of a workpiece placed within or near the coil. Friction from these currents elevates the temperature of the workpieces to be heated.

Benefits of Induction in Automotive Manufacturing

Process repeatability, accuracy, energy efficiency and speed are four hallmarks of induction heating for virtually any application. Additionally, induction heating delivers heat to the targeted part, not the atmosphere around it, so there is no risk of distortion.

automotive manufacturing Application Notes

Select from our collection of automotive manufacturing notes, taken from years supporting our customers. Read how we helped to solve their process heating challenges.

image: Preheating Steel Tubes Prior to Bonding Preheating Steel Tubes Prior to Bonding

To heat steels tubes for a bonding application; the end product is a bushing for large trucks. Induction would replace an oven for this client.

image: Preheating Rod Assemblies for Welding Preheating Rod Assemblies for Welding

The client had been using torches for preheating. However, due to process improvements thanks to new automation in their facility, torch heating became too slow. This resulted in a backlog that kept them from maximizing their throughput.

image: Induction Preheating Steel Laminate Parts Induction Preheating Steel Laminate Parts

The c-lams are inserts for an automotive industry application. In production the robotic pick-and-place will occur for plastic overmolding after heating by induction.

image: Heating Automotive Battery Cables for Adhesive Melting Heating Automotive Battery Cables for Adhesive Melting

Temperature indicating paint was applied to the parts, and it took 10 seconds to heat the various styles of the part to the targeted temperature. This testing achieved the client's time and quality objectives.

image: Braze a Copper Tube and Brass Fitting (fuel containment) Braze a Copper Tube and Brass Fitting (fuel containment)

How to braze copper using a custom-designed single position multi-turn helical coil built to generate the required heating for the copper brazing application.

image: Brazing steel flange and shaft assemblies (aerospace and automotive applications) Brazing steel flange and shaft assemblies (aerospace and automotive applications)

Induction brazing is a repeatable process that isn't as labor intensive as a flame often is. The process can heat the assembly rapidly and more energy-efficiently than a torch without the safety risks that come with an open flame

image: Brazing a steel tube and fitting to create an automotive valve Brazing a steel tube and fitting to create an automotive valve

Customer's client was unhappy with the results from MIG welding, which drove them to look at induction as an alternative process. Induction heating proved to be a fast, repeatable heating method for the application...

image: Induction preheating a steel automotive transaxle (welding) Induction preheating a steel automotive transaxle (welding)

The steel axle was painted with temperature indicating paint and a thermocouple was attached to the part.

image: Heating lead battery terminal for removal (recycling) Heating lead battery terminal for removal (recycling)

A single turn helical coil is used for this heating application. The lead terminal is placed inside the coil and is heated for 20 seconds.

image: Heat a compacted litz wire bundle for stripping Heat a compacted litz wire bundle for stripping

A three turn helical coil is used for the wire stripping process. The litz wire bundle is placed in the coil for 3 seconds to strip the lacquer 0.75 (19mm) from the end of the bundle. The wire bundle is then scraped with a metal brush to remove the burnt lacquer...

image: Heat aluminum for brazing an automotive assembly Heat aluminum for brazing an automotive assembly

A multi turn pancake coil is used to heat the joint between the aluminum tubing and boss. The joint heats to temperature in 1.5 minutes and the braze ring melts forming a clean brazed joint.

image: Brazing automotive tube assemblies Brazing automotive tube assemblies

A four turn split helical coil is used to heat the steel assembly to 1400°F (760°C) for 85 seconds. The coil design allows for the steel fitting to expand away from the steel tube which allows braze to flow through the joint.

image: Shrink Fitting Magnetic Steel Pistons Shrink Fitting Magnetic Steel Pistons

Using induction for shrink-fitting magnetic steel pistons onto a chrome shaft; the client was using an unreliable handheld induction system and wanted a higher quality induction shrink-fitting solution.

image: Heating a motor prior to adding an injection molded part Heating a motor prior to adding an injection molded part

Induction heating enables quicker process times with increased production rates versus a gas-fired oven. Ovens require long heat-up and cool-down times

image: Soldering a Radio Antenna Soldering a Radio Antenna

To heat a coaxial antenna assembly to 600°F within 2 seconds for a soldering application. The goal to improve on an existing procedure with a soldering iron which required 10 to 15 seconds.

image: Soldering Solar Flex Circuits Soldering Solar Flex Circuits

Heat multiple joints on solar flex circuit strips to 500°F (260°C) within ten seconds for a soldering application.

image: Bonding Steel Wire; Rubber Molding Bonding Steel Wire; Rubber Molding

To heat steel wire embedded in rubber molding for a bonding application in the automotive industry

image: Induction Bonding Adhesive to a Steel Washer (Automotive) Induction Bonding Adhesive to a Steel Washer (Automotive)

Bonding with induction heated a steel washer to the target temperature to enabling adhesive curing; it will be part of an automated process for an automotive industry application

image: Shrink fitting an automotive aluminum motor housing Shrink fitting an automotive aluminum motor housing

Induction shrink-fitting is fast, presents significant energy savings over an electric oven, requires a more modest footprint than an oven and can be easily integrated into an automated process

image: Heating steel liners (engine head) Heating steel liners (engine head)

Precise direct heat to disengage the aluminium quickly and cleanly. The aluminium casing is recycled and reused thereby reducing scrap and cutting costs.

image: Induction Bonding Plastic with a Steel Gasket (Automotive) Induction Bonding Plastic with a Steel Gasket (Automotive)

Induction bonding enables rapid heating, can easily be integrated into the client's manufacturing process due to modest space requirements and delivers a highly repeatable process.

image: Metal-to-Plastic Insertion with a Steel Insert Metal-to-Plastic Insertion with a Steel Insert

The power was turned on for five seconds and the part was monitored during heating and for 15 seconds after.

image: Shrink Fitting A Gear to a Shaft Shrink Fitting A Gear to a Shaft

The customer was using a torch, which can lead to inconsistent part quality. Induction's precise heating means the client can count on consistent results in their process

image: Shrink Fitting an Aluminum Motor Housing Shrink Fitting an Aluminum Motor Housing

The customer was using a cold press, but it was creating part defects. This was resolved with induction heating: the process took just two minutes compared to 40 minutes and they were able to achieve their targeted production rate.

image: Heat automotive seat springs to powder coat Heat automotive seat springs to powder coat

Even heating of the spring before dipping provides uniform flow and provides consistent thickness of the nylon coating

image: Heating of steel rivet ends (turbines) Heating of steel rivet ends (turbines)

Heating steel rivets prior to head forming

image: Sealing a Nylon Shell for a fuel vapor Assembly Sealing a Nylon Shell for a fuel vapor Assembly

Filter modules are assembled on the fixture with ring gasket. Pressure is applied to the modules, modules are rotated and induction heating is started. After 10-12 seconds, heating is halted and the modules are removed from the fixture.

image: Hardening Seat Belt Parts Hardening Seat Belt Parts

A four-turn helical concentrating coil is specially designed to deliver uniform heat to the steel seat belt retraction gear.

image: Bonding Rubber Gaskets to a Steel Gas Intake Manifold Bonding Rubber Gaskets to a Steel Gas Intake Manifold

To bond rubber gaskets to the top and bottom of a steel gas tank assembly.

image: shrink-fitting a carbide ring into a valve seat shrink-fitting a carbide ring into a valve seat

A three turn helical coil is used to heat the steel valve seat. The steel valve seat is placed in the coil and heated for 50 seconds to enlarge the center hole & drop the carbide ring in for the shrink-fitting process.

image: Heat the end of catalytic converter for weld testing Heat the end of catalytic converter for weld testing

Heat the end of lorry catalytic converter exhaust system. The assembly must be held at target temperature for 200 hours, whilst the assembly is vibrated to test the weld strength

image: Shrink-fitting auto turbo charger impeller blades onto an aluminum shaft Shrink-fitting auto turbo charger impeller blades onto an aluminum shaft

Induction heating provides repeatable results, reduced cycle time, lower consumables cost and even distribution of heating

image: Shrink fitting aluminum pulley to insert inner bearing Shrink fitting aluminum pulley to insert inner bearing

A three turn helical coil is used to heat the aluminum pulley. The pulley is heated to 464 °F (240 °C) in 20 seconds to expand the inner diameter and then the inner bearing is inserted to form the completed part.

image: Curing Alumium Car Molding Curing Alumium Car Molding

Automotive manufacturers are constantly searching for cost-effective production technologies.

image: Inserting a piston stop with o-ring into an oil pump assembly Inserting a piston stop with o-ring into an oil pump assembly

Induction heating provides increased production speed, simpler tooling for customer, hands-free heating that involves no operator skill for manufacturing

image: shrink-fitting an assembled wrist pin into a connecting rod shrink-fitting an assembled wrist pin into a connecting rod

Induction heating provides more accurate control of heat vs a flame burner, it heats only the knuckle, not the whole part, it prevents discoloring due to lower temperature used and increases productivity due to repeatability & ease of operation. A foot pedal & timer is used.

image: Bonding of electric motor shaft to nylon face fan Bonding of electric motor shaft to nylon face fan

Induction heating provides hands-free heating that involves no operator skill for manufacturing, only the metal shaft is heated so the motor is not affected, increased production due to rapid heating, decreased failure rate, originally used glue which ran into motor and caused failure and stronger bond

image: Heating Four Inserts Simultaneously Heating Four Inserts Simultaneously

The brass inserts are to be heated prior to insertion into a plastic automotive sub assembly

image: Case Hardening of Armature Shaft Case Hardening of Armature Shaft

A five turn helical coil is used to heat the gear end of the shaft to 1700°F

image: Shrink fit a motor shaft and roller Shrink fit a motor shaft and roller

Processing with induction heat saves power and time. The complete tube does not have to reach the desired temperature as it does when heating with an oven. Being able to selectively heat a zone allows for a much quicker transfer of heat.

image: Brass Inserts Brass Inserts

Heating is to be accomplished within 5 seconds, and can be done in a helical coil since pick and place manufacturing is employed.

image: Bonding Rear View Mirror Brackets to Windshield Glass Bonding Rear View Mirror Brackets to Windshield Glass

A unique four-over-four double wound pancake coil is used for the bonding application.

image: Bonding Automotive Trim Vinyl Covering Bonding Automotive Trim Vinyl Covering

Heating to 500°F is accomplished through the use of the unique coil; molding is continuously processed at a rate over 20 feet per minute.

image: Curing Adhesive on Steel Motor Shaft for Bonding Curing Adhesive on Steel Motor Shaft for Bonding

A complex two coil system, shield and stud systems used to provide proper axial alignments of the shaft & coil while allowing the fixture to be open for removal of the shaft.

image: Pre-heating a Truck Axle Seam for Welding Pre-heating a Truck Axle Seam for Welding

To pre-heat the seam of a truck axle to over 300°F within 15 seconds for a welding application and maintain temperature within the welding zone

image: Heating an Engine Valve Head for Stress Testing Heating an Engine Valve Head for Stress Testing

To heat the face of an engine valve head to 900°F and maintain the temperature for an extended time, high temperature stress test.

image: Brazing Oil Suction Assembly with Copper Ring Brazing Oil Suction Assembly with Copper Ring

To heat an oil suction assembly (steel tubing and filter cap) to 1,850°F (1010°C) within 15 seconds for a brazing application.

image: Shrink Fitting Cam Shaft Gears Shrink Fitting Cam Shaft Gears

To heat aluminum and steel camshaft gears to over 500°F within 4 minutes for a shrink fitting application.

image: Heating Aluminum Auto Trim for Adhesive Curing Heating Aluminum Auto Trim for Adhesive Curing

To heat various sizes of aluminum auto trim to 500°F (260°C) at a rate of 30 ft. (9.1m) per minute for curing an adhesive.

image: Inserting Steel Studs into a Plastic Tail Light Inserting Steel Studs into a Plastic Tail Light

To heat threaded steel studs for insertion into a plastic tail-light assembly at 450°F.

10 Heating Application Notes

We have collected these 10 popular Application Notes to help you understand the many ways induction heating can improve your heating processes.

10 Automotive Application Notes

We have collected these 10 popular Application Notes to help you understand the many way induction heating can improve your precision automotive manufacturing processes.