First, thicker metal requires more heat to fully penetrate welds, which can lead to distortion, cracking and residual stress, especially in high-strength steels or cast metals. Second, preheating is often needed to avoid thermal shock and prevent cracking caused by trapped hydrogen, which can enter the metal during the welding process from moisture or grease on the surface and even in the air.  Improperly stored welding consumables can also contribute to welds cracking. Preheating controls the temperature of the part and slows the cooling rate, giving hydrogen more time to escape.

Complex geometries for parts like wheel hubs cause their own issues. Recesses, spokes and bearing surfaces can make consistent weld access and heat distribution challenging – especially for robotic welding systems. Using induction to preheat these parts solves several of these problems. It provides precise, fast and uniform heat and the process can be automated. 

Benefits of Using Induction Preheating:

• Speed – induction heats a part faster than any conventional method. Time spent on preheating can be up 80% faster, depending on the part size and target temperature.
• Precision – heat only the portion of the part that is needed without overheating nearby surfaces.
• Uniform –  even distribution of heat minimizes thermal stress, prevents cracks and distortion, which is critical for thick or high-strength materials.
• Repeatability – automatically set and repeat exact heating and hold times.
• Control – qualify your process and assure quality for industries like automotive, rail and heavy truck manufacturing.
• Energy efficiency – more than 90% of energy used to heat is converted. Gas or flame, by comparison, converts only 30-50%. In addition, you’ll keep your shop cooler since less heat is lost to the shop floor.
• Integration-ready – our systems can be fully automated and integrated into welding cells, providing consistency without human error and a faster process in your shop.
• Less part handling – parts heat precisely and cool quickly, reducing the need to move parts between preheat and weld stations, thus lowering the risk of contamination or misalignment.

Induction Preheating vs Traditional Heating

Unlike torches or ovens, induction heating delivers controlled, uniform preheat in less time — with no open flame, no emissions and no guesswork. Bring your parts up to temperature using induction heating cables and generators before welding for faster and cleaner, safer and more consistent welds.