Induction Heating Systems | MillerWelds

Heating Equipment

Induction Heating

The right system for your heating needs

Why Induction Heating?

Induction heating is easy to set up, offers a fast time-to-temperature, and delivers exceptional heating efficiency, accuracy, and uniformity in part temperature. In addition, induction offers safety benefits compared to open flame and resistance heating methods.

Applications

  • Preheating and maintaining weld temperature
  • Hydrogen bake-out
  • Post-weld heat treatment (PWHT) up to 1450° F
  • Shrink-fit processes
  • Various other applications which requires heating

Industries

  • Oil and Gas
  • Structural
  • Power plants
  • Petrochemical/Refineries
  • Process/Power Piping
  • Pressure vessels
  • Shipyards
  • Mining

Plate Induction Heating

Infrared Plate Induction Heating
This highly efficient technology uses non-contact heating to induce heat electromagnetically rather than using a propane torch or resistant heating.  With induction, the part becomes its own heating element, heating from within.  This makes induction very efficient since little heat is lost in the process.
Time to temperature is dramatically faster than flame or resistance heating -- reducing cycle time. Setup and tear down times are quick and unlike flame or resistance, induction allows continuous heating and fabrication.
Induction heating lowers operational costs because reaching target temperatures is dramatically faster, resulting in reduced consumable costs and labor expenses. In addition, it eliminates the expense of fuel gases, fire watch personnel*, and heating subcontractors.
Quality IconProvides exceptional joint temperature uniformity.  Induction eliminates the inconsistencies and quality issues associated with flame or resistance heating.
Welders are not exposed to open flame, explosive gases, and hot elements associated with flame and resistance heating.  Induction’s method of heat transfer results in a cooler environment that reduces operator fatigue and improves work conditions.  

Compare Induction, Flame and Resistance Heating Methods

 
INDUCTION HEATING
FLAME HEATING
RESISTANCE HEATING
SETUP/TEARDOWN ✔ EASY
20 minutes or less per joint. Teardown time is fast, as induction tools can immediately be moved to the next joint without cooldown time.		 ✔ EASY
 		 ❌ COMPLEX
Approximately 3 hours per joint. Teardown times are also lengthy, as crews must first wait for the heating equipment to cool.
TIME TO TEMPERATURE ✔ FAST
20 minutes or less per joint		 ❌ SLOW
Up to 3 hours, depending on part/material size and thickness 		❌ SLOW
Up to 3 hours, depending on part/material size and thickness
JOINT TEMPERATURE UNIFORMITY ✔ EXCEPTIONAL
Thorough and even heat profile		 ❌ POOR
Subject to hot and cold spots		 ❌ MARGINAL
HEATING EFFICIENCY ✔ EXCEPTIONAL
90% efficient		 ❌ POOR
Much heat lost to air; reheating needed after breaks and off hours		 ✔ GOOD
Marginal heat lost to air
SAFETY ✔ EXCEPTIONAL
Tools do not heat up; no toxic byproducts or noise		 ❌ POOR
      
  • Risks burn injuries, fires and explosions
    •   
  • Excessive noise levels
    •   
  • Toxic, combustible byproducts
 ❌ MARGINAL
      
  • Ceramic pads are as hot as the work surface, bringing risk of burn injuries
    •   
  • Damaged/incorrectly used heating tools bring risk of electric shock
    •   
  • Inhaling insulation fibers/particles is a health hazard
OPERATING COST ✔ LOW
      
  • Delivers strong return on investment
    •   
  • Electricity cost: $5/hr
    •   
  • Induction air-cooled cables and air-cooled quick wraps are ruggedly constructed for repeatable uses
 ❌ HIGH
      
  • Fuel cost: $50/hr
    •   
  • Fire-watch personnel must often be hired*
 ❌ HIGH
      
  • Preheating contractors can charge up to $2,000 per joint, and final project costs often exceed original bid pricing
    •   
  • Requires installation of electrical infrastructure
    •   
  • Ceramic pads require frequent replacement
    •   
  • Used insulation is considered hazardous waste; proper disposal is costly

Products

ArcReach Heater

8 kW system for preheat and bake-out applications. System requires an ArcReach welding power source.

ArcReach Heater

ProHeat 35

35 kW system for preheat, hydrogen bake-out, post-weld heat treatment and various other heating applications. System requires 3-Phase, 50/60 Hz power.

ProHeat Induction System Pipe Application
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Articles and Videos

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New Preheating Technology for Rolled Pipe in Fabrication Shops

The majority of pipe welds completed in fabrication shops are rolled, and it's easy to understand why. Rotating pipe while welding provides many benefits, including ease of achieving quality welds by eliminating out-of-position welding; reduced welding operator fatigue; and improved productivity from higher wire feed speeds and increased deposition rates.
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When Preheating Before Welding, How to Choose the Right Equipment

Welding preheat equipment such as air-cooled cables and a new heating tool for induction, deliver flexibility and efficiency.
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Debunking Four Common Myths About Induction Heating In Welding Applications

Induction heating helps address many of the safety, efficiency and quality concerns associated with some other methods for preheating pipe. However, some common misconceptions persist.
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Quality Is Critical in Transmission Pipeline Welding — and Induction Heating Can Help

Induction heating offers quality, efficiency and safety benefits for heat treatment of steel in transmission pipeline projects.
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Think Beyond Pipe Welding for Induction Heating

How does induction heating work for applications beyond pipe?
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Preheat in Welding: What Is It and When Should You Use It?

Preheating in welding is important in many applications. Learn about the benefits and drawbacks of four common welding preheat methods.
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How To Control Hydrogen in Welding

From filler metal selection to proper preheat, learn some tips to help eliminate hydrogen-assisted cracking in welding.
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Welding With Induction Heating Improves Consistency and Saves Time

Using an induction heating system for welding preheat and post-weld stress relief can save time and improve productivity.
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Apex Steel Saves up to Two Hours Per Welder Every Day With Remote Control Technology

Structural steel contractor improves productivity and jobsite safety with Miller® ArcReach® technology.
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Welding Preheat Time Reduced in Lambeau Field Structural Steel Project

Induction heating delivers more consistent heating while improving productivity and safety in structural welding applications.
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Miller Preheating Technology for Roll-Welded Pipe Increases Quality, Productivity and Safety

Gaining consistency in preheating rolled pipe, or flat plate or seam welds, without the hassle and hazards of open flames, increases safety and efficiency.

Heat Parts Faster and More Consistently with Induction Heating

Induction heating provides great consistency in heating, faster time to temperature of the part, ease of use and safety in operation.

Miller Induction Heating - Where it Works

Learn more about applications for induction heating.

Go Beyond Flame Heating: ProHeat™ 35 Induction Heating System

Flame means problems with temperature consistency and safety. Solve them with a Miller ProHeat 35 Induction Heating System.

Miller Induction Heating - How it Works

This introduction to induction heating in welding applications will explain how it works and what it is.

The Lambeau Episodes 5: Induction Heating in Structural Steel Applications

Miron Construction used Miller induction heating throughout the Lambeau Field expansion project.

Topp's Mechanical: Induction Heating

Miller visits with Topp's Mechanical to discuss their use of Miller's induction heating technology in the ProHeat 35.

Easily Achieve Targeted Preheat Temperatures on Moving Parts using Induction Heating from Miller

The Miller ProHeat™ rolling inductor heating system is a simple and cost-effective heating process.

ProHeat™ Rolling Inductor Provides Safer Alternative to Preheating Rolled Pipe

Preheating is critical to achieve high weld quality; it eliminates moisture and reduces the opportunity for hydrogen cracking.

Induction Heating Cuts Preheat Time, Provides Uniform Heating for Swartfager Welding, Inc.

Swartfager Welding has turned to induction heating with ProHeat 35 for many of its preheating, interpass temperature control and stress relieving applications.

Induction Heating Proves Easy to Use for Topp's Mechanical

Miller visits with Topp's Mechanical to discuss their use of Miller's induction heating technology found in the ProHeat 35.

Topp's Mechanical: Induction Heating and Welding P1 Headers

Miller visits with Topp's Mechanical to discuss their use of Miller's induction heating technology found in the ProHeat 35.
*As specified in ANSI Z49.1, Supervisors shall assure that fire watchers are assigned and hot-work authorization procedures are followed where required.