Luoyang HongtengIntermediate frequency induction furnace
Traveling Wave Induction Heating: Principles, Applications, and Advantages Introduction When it comes to high-power induction heating applications, the use of single-phase induction coils often proves insufficient. For larger loads and better power balance, three-phase power supplies are typically applied. Although these setups do not represent a “true” three-phase system, they allow engineers to achieve higher efficiency in industrial induction heating systems. However, conventional multi-layer induction coils face challenges. The outer layers of the coil naturally heat the inner layers, leading to reduced power factor due to the increased air gap between the outer coil and the workpiece. While external flux-guiding techniques exist, they cannot effectively eliminate this limitation. To overcome these drawbacks, researchers at Aston University, Birmingham, have been developing an innovative solution: traveling wave induction heating. This emerging method promises to revolutionize the field and expand applications across multiple industries. The Principle Behind Traveling Wave Induction Heating The concept is best understood by drawing parallels with a traditional three-phase induction motor: In a standard motor, windings are distributed in multiple slots. When connected to a three-phase power source, these windings generate a sinusoidally distributed magnetic motive force (MMF) that rotates at a certain synchronous speed. The synchronous speed n...
Induction Furnace Melting Steel: My Real-World Grind Testing the Best for Your Ops in 2025 Hey there, steel melter—yeah, you, the one who’s probably elbow-deep in a failed pour right now, staring at lumpy slag and wondering why your setup keeps overheating or wasting power like it’s going out of style. I feel ya, pal. I’ve been exactly where you are. Back when I was ramping up my small casting shop, I’d spend nights cursing my old rig that couldn’t hit consistent melts for steel without burning through energy or risking a blowout. “Why does this have to be such a headache?” I’d gripe to my buddy over beers after another botched batch. As someone who’s clocked years testing gear for everything from hobby pours to industrial runs, I know the frustration of sifting through junk to find something reliable. So, I hunkered down, burned through my budget on trials (and a few crucibles), and narrowed it down to the real MVPs for induction furnace melting steel. If you’re hunting solid setups for clean, efficient steel melts—whether for scrap recycling or precision casting—hang tight. I’ll spill my unfiltered test notes, the highs and lows, and why I’m rock-solid confident these...
Reactor coils After passivation, high-quality copper tubes are wrapped with high-voltage-resistant insulation material. After forming using specialized tooling, the entire tube is wrapped with high-temperature, high-voltage insulation material. This ensures a high breakdown voltage and a long service life. A reactor, also known as an inductor, generates a magnetic field within the space it occupies when current flows through a conductor. Therefore, all current-carrying conductors generally exhibit inductance. However, the inductance of a long, straight conductor carrying current is small, and the magnetic field generated is weak. Therefore, a typical reactor is a solenoid formed by winding wire, known as an air-core reactor. Sometimes, to increase the inductance of this solenoid, an iron core is inserted, creating an iron-core reactor. Reactance is categorized into inductive reactance and capacitive reactance. The more scientific classification is that inductive reactance (inductors) and capacitive reactance (capacitors) are collectively referred to as reactors. However, because inductors existed first and were called reactors, the term “capacitor” today refers specifically to inductors, while “reactor” refers specifically to inductors. Product Description: Reactor coils are made from high-quality copper tubes that have undergone a passivation treatment and are then wrapped with high-voltage-resistant insulation material. After forming using specialized tooling,...
Temperature uniformity Most hot working processes (forging, forming, or extrusion) depend heavily on workpiece temperature uniformity, as this affects die life and metallurgical quality. While this uniformity can often be achieved by slowly heating the workpiece or placing it in a separate holding jacket or soaking chamber, this approach conflicts with the requirements of high productivity and minimal floor space. The designer’s challenge is to maximize power input while maintaining the required low surface-to-center temperature differential (without burning the heated surface area). Therefore, a deeper understanding of heat flow is essential (another requirement being to limit the mechanical stresses induced in the billet during heating). Input power The classic problem of temperature distribution on a cylindrical surface with constant power input was solved by Carslaw and Jaeger and later refined by Baker. These solutions are discussed in this chapter. It was shown there that after a transient temperature increase, the temperature distribution becomes parabolic, and the temperature profile remains constant as the temperature throughout the part increases at the same rate. The curves summarized in this chapter clearly demonstrate this: these curves are crucial for understanding the induction heating process. They show that the temperature difference between the surface and...
Main Types of Induction Heating and Their Application Trends As an efficient, clean, and controllable heating method, induction heating has been widely used in various industries, including metallurgy, machinery, electronics, and new energy. Based on different process requirements and application scenarios, induction heating can be divided into four major types, each with its own unique heating characteristics and applicable scope. 1. Forging Through-Heat Heating Forging through-heating is one of the most basic applications of induction heating. It is primarily targeted at workpieces with large volumes and long heating cycles, such as large forgings, die forgings, and annealing workpieces. This type of heating typically uses a lower frequency to ensure uniform heat penetration into the metal and achieve overall temperature consistency. Applications: Heavy machinery manufacturing, shipbuilding parts, automotive engine crankshafts, and mold heat treatment. Technical Advantages: Uniform heating avoids excessive thermal stress in the material. Controllable energy consumption makes it more efficient and environmentally friendly than traditional flame heating. Suitable for large-scale, long-duration continuous operations. 2. Medium-Frequency and High-Frequency Surface Hardening Heating Surface hardening is a major advantage of induction heating. Through medium-frequency or high-frequency heating, the workpiece’s surface heats up rapidly and then cools, forming a high-hardness hardened layer while...
Furnace Temperature Control Because it is the charge (workpiece) temperature, not the furnace temperature, that needs to be controlled, this title, while inaccurate, has been retained due to its widespread use. According to metallurgists, the goal is to achieve a given surface temperature for the charge and maintain this temperature until a specified temperature uniformity is achieved throughout the charge, or to vary the charge temperature according to a specified heating and cooling cycle. In both cases, charge temperature uniformity is required throughout the furnace. The charge interior should reach a given temperature but not exceed it. The reason is simple. For each specific process (rolling, forging, bending, extrusion, annealing, heat treatment) and for each specific material, there is a minimum temperature that must be achieved for the process to proceed smoothly. Temperatures exceeding this minimum temperature by a significant margin not only waste heat but also often have undesirable consequences, such as excessive scale, decarburization, and operational difficulties. 2. Temperature Control Throughout the Furnace If every exposed surface of the charge receives an equal amount of heat per unit time, then temperature uniformity is achieved throughout the furnace. This applies to batch furnaces. In continuous furnaces, the temperature...
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Small Medium Frequency Induction Furnace
Aluminum/Copper Ingot Continuous Casting Line
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