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Induction heating equipment is one of those areas that many of us have to know more about. We need to know when and the way to apply this technology, if it is the correct one for the job and tips on how to buy it if we have to do so. Let’s be taught more.

Power Supply

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

More energy is just not necessarily better. Matching the facility and frequency is the key. While more power permits you to heat faster, it may also melt the surface or produce a deeper sample (there is also more danger of by means of hardening), and it is harder to control grain growth.

Frequency

High frequency within the form of alternating current is passed via the coil to create a magnetic subject producing eddy currents. These are generated within the metal under the surface, and the resistance to this present 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 perform of frequency might be useful. This information is application-specific and dependent on each energy density and heat time however is considered typical of what’s found within the industry:

@ 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 operate of part diameter and the resistivity of the material. There’s an optimum depth of present penetration range, which is what each producer strives to provide.

Higher frequency has a definite advantage when you may have marginal prior part microstructures (annealed or normalized). Higher frequency permits the concentration of more energy near the surface of the part, avoiding lengthy heating times or necessities for higher power density (more expensive by way of $/kW).

Tuning

Tuning (energy-provide load matching) is a vital consideration to achieve the desired case-depth profiles and for overall 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 considered on a meter panel on the power supply.

The goal is to have a system that requires a minimal amount of tuning, which becomes more necessary as energy levels approach the maximum nameplate rating of the facility supply. For consistency of heating, the facility supply should be tuned in order that it is not running to its limit.

Computer-managed and recipe-chosen computerized capacitor contactors can be used to load match when many different workpiece sizes are heat handled on the same piece of equipment. Many power-provide manufacturers design a tuning window that lets you 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 workpieces have their own operate, form and properties. Coils (inductors) are water-cooled copper tubing or machined from stable copper blocks. They are designed and built specifically to satisfy the metallurgical necessities and production rates of the workpiece. Coils require periodic upkeep (repair) and must be suitable for the applications whether it be scanning, static heating or single-shot heating.

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