While there are many manufacturers, the principle behind induction melting is the same: a high voltage electrical source from a metal coil induces a high current in the metal, low voltage, or a secondary coil. Induction heating transfers heat energy, allowing for efficient alloying or melting of different types of metals. Although the process minimizes melt losses, refining metal is not the best process. Depending on the metal, production size, and other crucial factors, an induction furnace manufacturer can opt for a channel or coreless system.
Types of Induction Furnaces
A coreless induction furnace manufacturer ensures the coil, which acts as the heart, consists of a hollow section of high conductivity, heavy-duty copper tubing looped into a helical coil. The steel shell contains the coil shape, and a magnetic shield provides extra support against overheating. The water-cooled coil uses a recirculated and cooled ring in a designated cooling tower.
On the other hand, a channel induction furnace manufacturer uses a refractory lined steel shell containing molten metal. The induction unit is attached to the steel shell and connected by a throat, forming the heating components of the furnace. The induction unit comprises an iron core in the shape of a ring wound around a primary induction coil, creating a single transformer in which the molten metal melts loops. This process affects a good stirring process, making this furnace ideal for metals with a low melting point or a superheating unit for metals with a higher melting point, like cast iron.
Now that you are familiar with the two types of induction furnaces, you can assess which one is suited for your production needs before reaching out to a particular induction furnace manufacturer. However, different furnaces are suited for varying uses, and you must make the right choice. The last thing you want is to spend more on an overpowered system when your application requirements require an underpowered system. Before visiting an induction furnace manufacturer, here are some factors to help you select a suitable system.
The Material Used to Make the Furnace’s Parts
Induction is a process that involves directly heating conductive materials such as metals. Although nonconductive materials are sometimes heated using a conductive scepter, it is easier to heat magnetic materials than nonmagnetic materials. If you want to heat nonmagnetic material, you need a more powerful furnace for excellent results. Low resistivity metals like aluminum and copper require more heating, so make sure you purchase from the ideal induction furnace manufacturer for optimal efficiency and product quality.
Depth of Heat Penetration
Another vital factor in guiding your decision is the depth of the heat penetration. Regardless of the induction furnace manufacturer you choose, the induced current is usually more intense on the surface. However, parts that require thorough heating or more significant amounts tend to take more time to heat than minor or thin materials. Every induction furnace manufacturer specializes in the channel or coreless furnaces, which are designed to melt different types of material for various purposes.
If you are dealing with large parts that need thorough heating, consider an induction furnace manufacturer with expertise in higher-power, low-frequency systems. However, if heating is only required at the surface, we recommend going for an induction furnace with higher frequency and lower power to enhance efficiency without compromising quality. Many manufacturers usually provide a manual that contains a description and how-to-use section, providing buyers with pertinent information before making a decision.
The power output of a particular induction furnace is determined by the relative speed used to heat your material. This means that your go-to induction furnace manufacturer needs to account for the rise in temperature, material mass, and heat losses from conduction and convection. If you do not know what to look for when checking the applied power, consult the manufacturer to help with the assessments.
A rise in Temperature is Required
The reality is that induction can generate quite a significant temperature change, hence the need for more power to accommodate the changes. This will impact your power-supply choice and furnace type. An induction furnace manufacturer can help you pick out a system that can account for the faster rate of change by recommending a furnace that meets the desired power requirement.
The coil, which is usually made from copper and is water-cooled, should follow the shape of your material while accounting for variables in the process. Coil design can impact the efficiency and effectiveness of the process, and that is why you need to consult an induction furnace manufacturer on optimal coil design that delivers the ideal heat pattern to your material in the most efficient way. A poorly designed coil heats your material slowly, producing unsatisfactory results and improper heating patterns. To avoid such issues, check with your induction furnace manufacturer if they offer flexible coils that have unique part geometries and work well with large parts.
Your Facility and the Footprint
Induction relies on a cooling system or chiller for effective cooling. A lower-power system generally requires a water-to-air heat exchanger, while a higher-power system requires a sizeable water-to-air heat exchanger or chiller. Additionally, ensure you have the work head or induction heating power supply space. This is a critical factor if you lack sufficient space in your facility since the work head and power supply don’t have to be placed in the same place. A reputable induction furnace manufacturer can recommend a system that suits your facility’s power supply, alleviating potential risks that arise from incompatibility.
Regardless of which induction furnace manufacturer you choose to supply your system, it is essential to consider their expertise in various applications. This also goes a long way in providing peace of mind and ensuring you get the most from the furnace. Additionally, some manufacturers conduct laboratory testing and offer customized solutions based on your desired heating requirements. This critical step alleviates all the guesswork from the selection process, allowing you to assess and account for the factors mentioned.