Induction bending
Induction bending takes over where cold bending methods reach their maximum capabilities. Induction bending is powerful, highly accurate and gives no cross-sectional distortion.
Induction bending is a very efficient and precise bending technique using heat in order to bend tubes, pipes and sections. It takes over where cold bending methods meet their limitations. The combination of speed, local heat and cooling allows for bending even bigger profiles. Pipes up to Ø1016 mm and standard structural sections of up to 1100mm.
The video shows the induction bending process:
Advantages
Induction bending reduces the risks of wall thinning and deformation of the cross section. It allows thin walled profiles to be bent in even tighter or larger radii. There is no friction between the profile and the machine; the profile’s surface is unaffected by the bending process. Tubes, pipes and sections can be curved in multiple radii in one length. Multiple radii reduce the amount of welded joints needed. No or less welded joints save time and costs.
Induction bending stands for quality, flexibility and precision.
Capacities
Our powerful 800KW induction bending machine enables us to bend a full range of pipes, tubes, beams, and sections.
Maximum capacities:
Pipes Ø 1016mm
RHS: 600 x 400 x25mm
SHS: 500 x 500 x 25mm
Tee bars: HEA 1000
IPE 1000 mm
Bending radius: 2.5xD to ∞xD (no radius limitation)
Materials
The following materials can be formed by induction bending:
- Carbon steel
- Stainless steel; Duplex, super Duplex
- Special steels, such as Inconel, Cruesabro, S690QL, etc.
Induction bending process
The straight pipe or section is placed in the machine bed by guiding it through three coils that match the shape of the profile and by gripping one end of the profile in the bending arm. The bending arm is set to the required radius.
Once the profile is in position the copper heating coil heats up to the required temperature (up to 1,100ºC) and creates a circumferential heated zone. The two adjacent coils with nozzles are cooling the profile by blowing cold air and spraying water on the surface. As the heating coil reaches the required temperature, the profile is gently pushed through the coils. The swing arm moves along with the profile and bends it in the required radius and shapes it into a bend.
Special feature
Kersten has developed a one of a kind large radius device; a special feature to bend pipes, hollow sections and bars in large radii up to radius 80,000mm. This allows us to use the induction bending technique for new applications such as infrastructural & building constructions.
The video below shows the induction bending process
Applications
Induction bends can be found in many applications where curved pipes and sections are required and precision and reliability is of great importance. These applications include the following industries:
- Industrial equipment
- Architecture
- Infrastructure constructions and steel building constructions (a.o. bridges, construction, art objects, roller coasters)
- Offshore energy (a.o. J-tubes, S-tubes)
- Oil & gas pipelines (onshore and offshore)
- Petrochemical
- Power generation
- Ship building
- Etc.
Post bending processes
Bending is often just a part of the total concept. We offer additional services to provide you with ready-to-build-in curved components.
- Co-Engineering
- Heat treatments (stress relieve, normalizing, quenching tempered)
- Destructive (mechanics) and non-destructive testing (NDT)
- Hydro pressure testing up to 700 bars
- According to EN1090-2 / EN14870 / EN13480 / EN12952 (other standards on request)
- 3D robot cutting
- Qualified welding
- Surface treatments
