Billet Heating: Induction Heating vs. Gas Oven Furnaces
Billet heating is a critical process used to facilitate shaping and forming in metal forging. To create metal forgings, metal forgers begin by heating the metal using one of the following billet-forming processes:
- Induction heating. This process uses electromagnetic fields to quickly and efficiently heat metal billets, which are electrically conductive materials. First, an alternating current passes through an induction coil to generate the electromagnetic field. This field induces eddy currents in the billet to uniformly heat the object.
- Gas oven heating. This involves placing the billets in a furnace heated through natural gas. The hot gas and radiating heat from the walls gradually heat the billets. This method is less precise and slower compared to methods like induction heating.
The heating method you use can significantly impact factors like quality, efficiency, and environmental impact. Read on to learn more about induction heating vs. gas oven furnaces and the advantages of using induction heating when forging metal billets.
Billet Forming Applications: When to Choose Induction vs. Gas Heating
While both gas heating and induction heating methods can be used for different forging and fabrication applications, industries such as aerospace, automotive, hand tools, and other precision manufacturing require high-precision processes and complete control over the heating environment and temperatures. For these applications, induction heating enhances surface quality and allows manufacturers to produce superior forged parts while meeting strict design parameters.
Advantages of Induction Heated Billets Over Gas Furnace Heating
The induction heating method has numerous benefits over heating metal billets in a gas oven, including efficiency, quality, and cost savings:
- Speed and efficiency. Induction heating is faster than heating billets in a gas furnace. This is because induction heats up the metal billets without requiring an external heat source. Induction methods can also efficiently heat billets to exactly the right temperature without long wait times or having to make corrections.
- Scale formation and surface quality. Induction methods minimize the risk of oxidation and scale, enabling smoother, cleaner surfaces. Gas furnaces, in contrast, expose billets to more oxygen at high temperatures, which can increase unwanted scale development.
- Cost and energy savings. Induction heating also offers significant cost and energy savings. It uses up to 50% less energy than traditional gas furnaces because less heat energy is wasted heating up surrounding air and surfaces. This reduces total energy expenditure during forging, leading to lower operational costs and a smaller environmental footprint.
How Cornell Forge Leads the Industry in Induction Heated Billet Forging
Once you determine that induction heated billet forging processes are the best fit for your industry and specific projects, you’ll want to choose a service provider that meets or exceeds your standards. Cornell Forge has been an innovative leader in metal forging for over 90 years, specializing in cutting-edge induction heating processes that provide total control over the heating process. We use state-of-the-art induction heating equipment and high-temperature monitoring systems to guarantee that every billet is heated to exactly the right temperature for optimal forming, bending, and shaping. We can heat billets in various sizes and materials, ensuring flexibility and efficiency in our forging operations.
We also offer comprehensive inspection and quality assurance services. We continuously monitor and refine our induction heating processes and maintain strict control over every step in the process. As a result, our clients have greater peace of mind regarding the quality and consistency of every forging they receive, from its internal strength and toughness to its surface finish.
Why Customers Choose Cornell Forge for Induction-Heated Forgings
Cornell Forge Company serves aerospace, automotive, defense, construction, and other industries with high-quality forging requirements. Our advanced induction heating capabilities and nearly a century of forging experience make us a leader in complex metal forging and production. Clients across industries trust us to provide efficient and environmentally responsible forging solutions. We also back those solutions with ISO 9001:2015 and PED certifications.
Contact us today to learn more about our capabilities or request a quote to start your order of forged metal goods.
