Induction Weld Preheating | MillerWelds

Take Control of Weld Preheating With an ArcReach® Heating System

Weld preheating methods like flame and resistance send projects out of control:

  • They’re expensive
  • They’re time-consuming
  • They increase safety risks

ArcReach® Heating Systems put you back in control. This induction heating equipment uses alternating electromagnetic currents to generate heat in workpieces, so welders can do their own preheating quickly and safely.

Flame and Resistance Heating Have Multiple Challenges

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Expense — Flame heating means paying $50/hour for fuel and hiring fire-watch personnel. Resistance heating can cost up to $2,000 per joint.
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Logistics — Subcontracted heating rarely coordinates with welding, causing delays and missed timelines.
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Time — Resistance heating has long setup and teardown times.
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Quality — Both flame and resistance heating produce uneven temperatures, which can reduce weld quality.
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Safety — Both flame and resistance heating increase the risk of burn injuries. Flame heating has fire and explosion risks.

Induction Heating Equipment vs. Flame vs. Resistance

 
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
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  • 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