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Induction heating equipment is a type of areas that many of us need to know more about. We need to know when and learn how to apply this technology, if it is the precise one for the job and how you can buy it if we need to do so. Let’s study more.

Power Supply

Power, expressed in kilowatts (kW), refers back to the induction energy-provide size. A power supply must be sized to heat a given mass or given surface space to a specific temperature within a specified time. A basic rule of thumb is that the surface area (exposed to the coil) used to determine the facility level is 6-12 kW/inch2. The prior part microstructure (annealed, normalized, quenched and tempered) will affect the facility density (kW/inch2) required. For example, a quench-and-tempered microstructure is optimum for many induction applications.

More energy shouldn’t be essentially better. Matching the ability and frequency is the key. While more energy permits you to heat faster, it can also soften the surface or produce a deeper pattern (there may be additionally more hazard of by way of hardening), and it is harder to manage grain growth.

Frequency

High frequency in the form of alternating current is passed by way of the coil to create a magnetic area producing eddy currents. These are generated within the metal under the surface, and the resistance to this current flow is the principal source for heating of the metal.

The next guideline for “relative” depth of penetration (depth of hardening or case depth) as a function of frequency is likely to be useful. This information is application-particular and depending on both energy density and heat time but is considered typical of what is found within the business:

@ 450 kHz the case depth developed is (approximately): 0.030-0.040 inch

@ 100 kHz the case depth developed is (approximately): 0.050-0.080 inch

@ 30 kHz the case depth developed is (approximately): 0.080-0.one hundred twenty inch

@ 10 kHz the case depth developed is (approximately): 0.090–0.200 inch

The depth of current penetration (hardened depth) is a perform of part diameter and the resistivity of the material. There is an optimum depth of present penetration range, which is what every producer strives to provide.

Higher frequency has a definite advantage when you might have marginal prior part microstructures (annealed or normalized). Higher frequency permits the concentration of more energy close to the surface of the part, avoiding lengthy heating instances or necessities for higher power density (more pricey in terms of $/kW).

Tuning

Tuning (energy-supply load matching) is an important consideration to achieve the desired case-depth profiles and for general power-system efficiency. This is done by adjusting the tap of a variable-ratio transformer or by adding/subtracting a portion of a capacitor to achieve the desired frequency and a balanced load match between amperes, volts and kW. These are typically seen on a meter panel on the facility supply.

The goal is to have a system that requires a minimal quantity of tuning, which becomes more important as energy levels approach the utmost nameplate ranking of the facility supply. For consistency of heating, the power supply needs to be tuned so that it is not running to its limit.

Computer-managed and recipe-selected computerized capacitor contactors can be utilized to load match when many different workpiece sizes are heat treated on the identical piece of equipment. Many energy-supply producers design a tuning window that permits you to make some modifications to the part size being run. When only one part is dedicated to a system, no tuning is required after initial setup and testing.

Coils

All workitems have their own perform, shape and properties. Coils (inductors) are water-cooled copper tubing or machined from strong copper blocks. They’re designed and built specifically to satisfy the metallurgical necessities and production rates of the workpiece. Coils require periodic upkeep (repair) and should be suitable for the applications whether it be scanning, static heating or single-shot heating.

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