Induction heating equipment is one of those areas that many of us need to know more about. We have to know when and tips on how to apply this technology, if it is the correct one for the job and the right way to purchase it if we have to do so. Let’s be taught more.
Power Supply
Power, expressed in kilowatts (kW), refers back to the induction energy-provide size. A power provide have to be sized to heat a given mass or given surface area to a particular temperature within a specified time. A general rule of thumb is that the surface space (exposed to the coil) used to determine the power level is 6-12 kW/inch2. The prior part microstructure (annealed, normalized, quenched and tempered) will affect the ability density (kW/inch2) required. For instance, a quench-and-tempered microstructure is optimum for many induction applications.
More power shouldn’t be essentially better. Matching the facility and frequency is the key. While more energy permits you to heat faster, it might also melt the surface or produce a deeper sample (there’s additionally more hazard of through hardening), and it is harder to control grain growth.
Frequency
High frequency within the form of alternating current is passed by way of the coil to create a magnetic field 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 operate 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 is discovered in the trade:
@ 450 kHz the case depth developed is (approximately): 0.030-0.040 inch
@ a hundred 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 present penetration (hardened depth) is a function of part diameter and the resistivity of the material. There may be an optimum depth of current penetration range, which is what every producer strives to provide.
Higher frequency has a definite advantage when you could have marginal prior part microstructures (annealed or normalized). Higher frequency allows the concentration of more energy near the surface of the part, avoiding lengthy heating instances or requirements for higher energy density (more costly in terms of $/kW).
Tuning
Tuning (energy-supply load matching) is an important consideration to achieve the desired case-depth profiles and for general energy-system efficiency. This is done by adjusting the faucet 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 viewed on a meter panel on the facility supply.
The goal is to have a system that requires a minimal amount of tuning, which becomes more essential as energy levels approach the utmost nameplate ranking of the facility supply. For consistency of heating, the power supply should be tuned so that it isn’t running to its limit.
Computer-managed and recipe-selected automatic capacitor contactors can be utilized to load match when many different workpiece sizes are heat treated on the same piece of equipment. Many power-supply producers design a tuning window that means that you can make some adjustments to the part measurement 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 perform, form and properties. Coils (inductors) are water-cooled copper tubing or machined from solid copper blocks. They are designed and constructed specifically to fulfill the metallurgical requirements 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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