How does induction bending work exactly?

Induction bending is a precise and efficient method used to bend pipes, tubes, and structural shapes. This technique leverages the principles of electromagnetic induction to heat and bend the material. Read more about it in this article!

The induction bending process: Step by step

The process of induction bending involves several key steps that ensure the material is bent accurately and maintains its structural integrity. Below, we outline the essential stages of the induction bending process:

1. Preparation 
   * Material Setup: The pipe, tube, or structural shape to be bent is securely clamped at both ends to prevent movement during the process.
   * Induction Coil Placement: An induction coil is positioned around the section of the material where the bend is desired
2. Heating
   * Induction Heating: An alternating current is passed through the induction coil, generating a rapidly changing magnetic field. This field induces electric currents (eddy currents) in the material.
   * Localized Heating: The eddy currents generate heat within the material due to electrical resistance. This heating is highly localized to the area within the coil, allowing precise control over the bending location.
3. Bending 
   * Controlled Heating: The material is heated to a specific temperature where it becomes pliable, typically in the range of 800 to 1100 degrees Celsius (1470 to 2010 degrees Fahrenheit) for steel, though this varies depending on the material being bent.
   * Bending Force: While the material is heated and in a malleable state, a bending arm or mechanism applies a force to bend the material to the desired angle. This is often done by rotating the material around a fixed bending radius.
   * Cooling: Once the material has been bent to the required angle, it is cooled rapidly, usually with water or air. This cooling solidifies the material in its new shape.
4. Post-Process 
   * Quality Inspection: The bent material is inspected for accuracy (dimensional control), wall thinning, ovality and hardness. Metallurgic inspection may be part of the QC-procedure.
   * Finishing: Additional processes such as trimming (cutting the tangents to the correct length) and beveling, might be performed to meet the specific customer requirements.

Benefits of induction bending

Induction bending offers several key advantages. First, it provides precise control over the bend radius and angle, ensuring high precision in every project. Additionally, the process is relatively quick and efficient, capable of handling large sections of material with lower forces than cold bending, resulting in less deformation. The quality of induction bending is also superior, producing smooth, continuous bends without the need for welds or joints, which maintains the structural integrity of the material. Furthermore, induction bending is highly versatile and can be applied to a variety of materials, including different types of steel, alloys, and other metals.

Induction bending is the solution

Induction bending stands out as the ideal solution for a wide range of applications due to its precision, efficiency, and quality. Cojafex, a leader in this field, offers unparalleled expertise and capabilities in several key areas. In pipeline construction, induction bending is essential for creating pipes used in oil, gas, and water transport, accommodating both large transport lines and smaller gathering lines. The oil and gas industry benefits from the production of various elbow fittings made from different kinds of steel, specifically for petrochemical plants. For subsea applications, Cojafex produces high-quality duplex and super-duplex bends, as well as clad pipe applications with Inconel cladding, ensuring durability and performance under extreme conditions. In power generation, induction bending is utilized for creating thick-walled large bends and smaller-sized bends in chrome steel and stainless steel, catering to both conventional and nuclear power plants. Lastly, structural engineering projects, such as bridges, buildings, and traffic signs, rely on the precise forming of bent shapes to ensure structural integrity and aesthetic appeal.