Professional Documents
Culture Documents
Copyright 1
988 ASM International
Stanley Zinn, Lee Semiatin, p 1-8
All rights reserved.
DOI: 10.1361/eoih1988p001
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w.asminternational.org
Chapter
Introduction
Electromagnetic induction, or simpl
y "induction," is a method of heating
electrically conductive materials such
as metals. It is commonly used in process
heating
prior
to metalworking,
and
in heat treating,
welding,
and
m
elting
(Table
1.1). This
technique
a
lso lends
itself to various
other
applica
tions
involving packaging and curing. The n
umber of industrial and consumer items
which undergo induction heating during
some stage of their production is very
large and rapidly expanding.
As its name implies, induction he
ating relies on electrical currents that are
induced internally in the material
to be heated-i.e.,
the workpiece. Th
ese
ications
ting
ng,
Steels
Table
1,1. Induction
and typical
products
Preheating
prior
to metalworking
Welding
Forging
Seam Welding
Gears
Oil-country
Shafts
tubular
Hand tools
products
Ordnance
Refrigeration
tubing
Extrusion
Line pipe
Structural
members
ng,
Shafts
heating
appl
Heat trea
Melting
Surface Hardeni
Air Melting of
Tempering
Ingots
Gears
Billets
Shafts
Castings
Valves
Vacuum Induction
Machine tools
Melting
Hand tools
Ingots
Through Hardeni
Billets
Tempering
Castings
Structural
"Clean" steel
s
Heading
members
Nickel-base
Spring steel
superalloy
Bolts
s
Other
fasteners
Chain links
Titanium allo
ys
Rolling
Slab
Annealing
Aluminum stri
p
Sheet (can, appliance, and
Steel strip
automotive
industries)
----------------------- Page 3---------------------2
ing:
Design,
medium
frequency (1 to 50 kHz), or
radio frequency (greater than 50 kHz).
Design,
Following the
acceptance of
induction
heating
for metal
melting,
other
applications of this promising technology were v
igorously sought and developed.
These included induction
surface h
ardening
of steels, introduced by
Midvale Steel (1927) and the Ohio
Cranksha
ft
Company (mid-1930's).
The
former company used a motor-generator for surf
q.
Cd
T -
I~.
O)
I~-
'
T
.
,
Q
(O
r~
r,-
94%
r,.O3
CO
O3
O~
O3
'T
90%
o~
OJ
85
%
80
O3
84%
85%
83%
r,3
t--
75%
m
(3
O
(O
O3
I.Ll
60
v_
40
/
,
/
540 Hz
180 Hz
I
SparkMotorEarly solid state
Variablegap
generator
tuned
generators
sets
solid state
ficiency
of
supplies
Fig. 1.1.
induction
Conversion
heating
ef
power
Integral
generator
motorgenerator
540 Hz
Early
solid
state
"10
Solid
C
state
cO
VariableO
tuned
(3
solid
(/)
O
state
Present
solid
state
1948
1963
1978
1953
1968
195
1973
1981
Year
Fig. 1.2.
Change in cost of i
nduction heating power supplies since 1948
(from R. W. Sundeen, Proceeding
s, 3gth
Electric Furnace Conference,
Houston, TX, AIME,
New
York,
1982, p. 8)
----------------------- Page 7---------------------6
:
um
alloys,
and
other
metals.
parts,
adhesives.
As in paint curing,
induction
heating of the metal parts to curing temperat
ures can be an excellent means
of achieving rapid bonding.
Metal-to-nonmetal
seals, widely used in vacuum
devices, also
rely heavily on induction heati
ng.
Semiconductor Fabrication.
The growing of single
crystals of germanium and silicon often relies on induction heating. Zone
refining, zone leveling, doping,
and
epitaxial deposition
of semiconductor m
aterials
also make
use of the
induction process.
Tin Reflow. Electrolytically deposited tin coatin
gs on steel sheet have a dull,
matte, nonuniform finish. Heating of the sheet
to 230 C (450 F) by induction causes reflow of the tin coating and
results in a bright appearance and
uniform
coverage.
Sintering. Induction heating is widely used in
sintering of carbide preforms
because it can provide the necessary high temper
ature (2550 C, or 4620 F)
in a graphite retort or susceptor with atmosp
here control. Other preforms of
ferrous and nonferrous
metals can be sinte
red in a similar manner with
or
without atmosphere protection.
ADVANTAGES OF INDUCTION HEATING
Prior to the development of induction heati
ng, gas- and oil-fired furnaces
provided the prime means of heating metals and
nonmetals. Induction heating
offers a number
of advantages over furnace
techniques,
such as:
Elements of
Heating:
Design,
and Applications
Bar section,
in.
4
5
8
v
I
I
I
I
o
Q
It)
C%1
(J
o
2 - -
2
O~
:
a l
Q)
t 1 - z:"
d
E
Induction
10
15
20
Bar section,
Fig. 1.3.
of
times
for
through
by
induction
and
gas-fired
echniques
as a function
cm
Comparison
heating
furnace
of
t
bar
diameter
.
e
Huchok,
(from
R.
Daugherty
and A.
A
Proceedings, 11th Biennial Conferenc
Industry, IEEE,
1973)
In
Ease
control
Reduced
quirements
Quiet,
ing
Low
ents.
of
that
automation
and
floor-space
safe,
conditions
maintenance
indu
re
and
clean
work
requirem
kpiece
ena
to
are
the
be
heated.
The
basic
phenom
to
the
9
----------------------- Page 11---------------------10
ating:
Design,
described by
in to
the
Elements of Induction He
Control, and Applications
same relationships
other ac circuits
that perta
or to
dc
current,
distance
with
The
ac current,
as
surrounds the
with
dc,
sole-
of Induction
Heating
1 1
The current is emerging from the
page. The relationship between
the directions of the magnetic f
ield and the current is expressed
by the "right-hand" rule (thu
mb
pointing in direction
of current, fingers giving
directio
n of magnetic
field).
Fig. 2.1. Magnetic field (lines
with arrows)
around
an electrical conductor
(cross-hatched
circle a
t center) carrying a current (from
D. Halliday and
R.
Resnick, Physics,
Wiley, New York,
| 966)
sleeve, to vary.
In his experiments in the
mid-1800's, Faraday found that
such
a variation
in flux induces a voltage.
For the present example, the voltage,
or electromagnetic force,
induced in
the
sleeve, Esleeve, is given by
E~te~v=
N (Aq,a/At)
where N
is the number
of turns
in
the coil and A ~ / A t
is the rate
at
which
the flux is changing, in webers (Wb) per second
. The above equation is known
as Faraday's
Law.
It has been pointed out
above that
the magnetic field strength associated
with an electric current varies with the ma
gnitude of the
current.
Thus
,
for
an ac current in a conducting wire or a s
olenoid coil, the maximum and minimum values of the magnetic field strength oc
cur at the same times as those
of the
current
(Fig.
2.4). At
a pea
k
or a valley of the
current
or mag
netic
field,
Aq,J A t
is equal
to zero.
By
examining
Fig.
2.4, it is apparent
that
----------------------- Page 13---------------------12
on Heating:
ations
Design,
Elements
Control,
of
and
Inducti
Applic
n
the
#oIcn)(xro2)
where
. . . . . . . . . . . . - - (a)
=
Copper
(b)
~
Iron
(~) Currentflowing awayfrom yo
Currentflowing towardyou
Fig. 2.3.
Effects of (a) nonma
gnetic
and (b) magnetic
bars
on the field
of magnetic
induction
(i.e.,
magnetic flux) within a
solenoid
coil
c
arrying an electric
current
(from
C. A. Tudbury,
Basics of Induction Heat-
nc., New
ing, Vol
York,
1960)
1,
John
F.
Rider,
by the
eddy currents is
equal
to Esleeve Rsleeve, or
leeve Rsleeve,
where Isleeve
= Esleeve/Rsleeve
m Ohm's
Law.
then
Is
, f r o
EDDY-CURRENTDISTRIBUTION
IN A SOLID BAR
For the thin-sleeve case, the induced edd
y currents assume a fixed magnitude
depending only on the coil current a
nd
geometry.
In contrast,
when
a
solid bar
is placed inside the coil, the
behavior is somewhat more complex.
This
situation
is best
visualized
by
imaging the
solid bar
to
consist
of
a
number of thin, concentric sleeves (Fig. 2.5).
The field of magnetic induct
ion
----------------------- Page 15---------------------14
tion Heating:
Applications
Elements of
Design, Control,
I
Induc
and
Coil current
Ma.gneti
c ~
~
"0
Time
of
Induction
Heating
15
is strongest in the space between the inner
diameter of the coil and the outer
diameter of the
outermost sleeve. A
certain amount
of flux passes through
the
outermost
whether
the magnetic
field
strength
is greater
or smaller
within
the
o
uter
sleeve, relative to the external field. This d
epends on whether the induced current in the outer sleeve tends to reinforce
the field or not.
If it strengthene
d
the
field, a higher voltage would be induce
d in the
sleeve, causing a higher
current.
This would result in a still stronge
r field, a higher voltage, etc., a situation
which certainly cannot
happen
.
Thus,
the magnetic field strength is
reduced within the outermost sleeve. Because
of this, the current induced in
the second sleeve from the surface is smaller th
an that in the outermost sleeve,
the induced current in the third
sleeve
is smaller than that in the second, and
so forth. In general, the magnitudes of the
induced currents decrease continuously from the surface irrespective of whethe
r the bar
is made of a magnetic
or a nonmagnetic material.
This pheno
menon is known
as "skin effect."
Mathematical determination of the current dis
tribution over the cross section of a bar,
let alone a more complicated
geometry, is a difficult task,
a
discussion of which is beyond the scope of this book.
For the simplest case which
can be analyzed- that
of a solid round
b a r - t h e
solutions demonstrate that
the induced current decreases exponentially from
the surface. The most important
result
from
such
solutions is that
they
allow
us to define an
effecti
ve
depth of the current-carrying layers. This dept
h, known as the reference depth
or skin depth, d, depends on the frequency of
the alternating current through
the coil and the electrical resistivity and rel
ative magnetic permeability of the
workpiece;
it is very useful
in gaging
the
ability to
induction heat
vario
us
materials
as well.
The definition of d i
s:
d
3160 pv~#f
(English units)
o r
d
5000
pv~
#f (metric units)
where d is the reference depth, in inches or
centimetres; p is the resistivity of
the workpiece, in ohm-inches or ohm-centimetre
s;/~ is the relative magnetic
permeability of the workpiece (dimensionless);
and
f is the frequency of the
Design,
Elements of
Inducti
Control, and
Appli
10
~
~
Iron at 815 C (1500 F)
Nichrome at 20 C (70 F)
1000
~ .
.
J J
J
E
.c"
Lead at 20 C (70 F)
Brass at 500 C (930 oF)
1.0
8
1
00
~
,5
-~
r
0.1
~
10
Iron at 20 C (70 OF)"
"
~
~
~
I
0.01
I I I I
10
104
I I I
I ' ~ L I I I
102
105
I
~
I
I ~
103
10
6
Frequ
ency, Hz
Fig. 2.6. Reference
depth for c
ommon materials
as a function of frequency
(from A. F. Leatherman
and D. E. Stutz,
"Induction Heating
Advances:
Application to 5800
F,"
NASA
Report SP-5071,
National
Aeronautics
and Space Administr
ation,
Washington,
1969)
the resistivities of conductors vary with temp
erature.
Furthermore,
fo
r magnetic
steels, permeability varies
wi
th temperature,
decreasing to
a v
alue
of
unity at and above the Curie temperature. A
lso in these materials, the reference depth below the Curie temperature increa
ses with power density as the
steel becomes magnetically saturated
and permeability decreases (Fig.
2.7).
Because of these effects, the reference dept
h in nonmagnetic materials
may
vary by a factor of two or three over
e heating range, whereas for magnetic
steels, it can vary
as much
20 times.
EQUIVALENT
R E S I S T A N C E
E F F I C I E N C Y SOLID
ROUND
BAR
The
to
concept
wid
as
AND
tant
quantities
in the technology of in
duction heating-namely,
equi
valent
resistance and electrical efficiency. The equ
ivalent resistance Req is the workpiece resistance which if placed in a series cir
cuit with the induction coil would
dissipate as much
heat
as all the
eddy currents
in the
actual workpiece.
In
other words, the power dissipated in the workp
iece would be equal to
12. Req.
For
a solid round bar,
it turns
out
that
the equivalent resistance is equal
to
the product
of N 2 and
the
resistanc
e
of a
sleeve o n e
reference
depth
thick
located at the surface: Req = p~'aKRzN2/A,
where a is the outer diameter
of
the sleeve (or solid bar),
A is the cr
oss-sectional area of the sleeve (=
d. w),
and KR2 is a factor (Fig. 2.8) to
ac
count
for
the variation
of electrical
path
of
Induction
Heating
17
Power density,
W/in. 2
10 3
10 4
10 3
I|.w|i
j
5 1 i
R i i l
I
100
10 2
E
c5
O
Q)
t c
10
t JE
J
J
.c
I
g,
O9
I
10
~
10 2
10 3
10 4
Power density,
kin)
depth
function of
W/cm 2
Fig. 2.7.
for
magnetic
Reference
steel
as
(s
a
Elements of Inductio
Design, Control, and Applications
1.0
v
0.9
0.8
0.7
"6
0
0
-
0.6
09
09
0.5
o
Q~
O.
0.4
/
0.3
l
0.2
0.1
J
/
0
0
10
22
12
14
16
6
18
8
20
24
Electrical
Fig. 2.8.
correction factor
Workpiece
used for
resistan
calculating
workpiece
resistance as reflected
in induction-coil circuit for solid round
bars
(from C. A. Tudbury,
Ba
sicsof Induction Heating, Vol
1, John
F.
Rider,
Inc., New York,
1960)
The equivalent resistance, or the workpiece
resistance as reflected in the coil
circuit as it is often called, allows the electri
cal efficiency to be calculated. The
efficiency ~/is the ratio of electrical energy di
ssipated in the workpiece to that
dissipated by the coil and workpiece:
Ic
2Req
Req
7/12Req
Rc +
i2Rc +
Req
of
Induction
Heating
1 9
erence depth,
a/d.
Careful inspection
of this plot reveals that KR2 increases
rapidly
for values of a/d
up
to ap
proximately 4. Above this value, there is
little increase in KR2 for big increases in
a/d.
Because a is a
fixed
number
for
a specific application,
the valu
e
of a/d
is determined by the
reference
depth d. Thus,
an increase in a/d
requires a decrease in d. Referring to the
equation for reference depth
(d ~
x/~#f),
it is seen that
increased fre
quencies are needed for higher values of a/d.
This has practical significance inas
much
as the cost of induction power
supplies increases with frequency.
The trend
shown in Fig.
2.8
f
or
KR2 versus a/d
forms the basis
for
the
2.54
254
106
i .
I
~ .
I
II
I
i\\',
...
I I I
III
X
~,
F)
~
~ k
~
~ , ~ ,
\
\
~,~
. Steelat 815 C (1500
~
Brassat500c(930F)
Brassat 20 C (70 F
)
Copper at 500 C (93
0oF).
~ ! V ~
Cpper at 20 C (70
F)
Steel at 500 C (930o
F)
-?
lO~
Steel at 25 C (75
F)
~
I
'~
1
-.~
\ ,
,
o
104
V \
\
103
0.001
0.1
10
\ \ \
\
0.O1
1.0
Diameter, in.
Fig. 2.9. Critical frequency
for efficient induction
heating of several
materials as a function
of b
ar size
(from A. F. Leatherman
and
D.
E.
Stutz, "Induction
Heating
Advances:
Application to 5800
F," NASA
Report SP-5071,
National
Aer
onautics
and Space Administration,
Wash-
ington,
1969)
Design,
Elements of Induction
Control, and Applications
cal frequency as a
function of diameter
for round
bars.
Figure 2.10
show
s
efficiency of heating as a function of this crit
ical frequency; note the similarity
between this plot and the plot in Fig. 2.8.
Here,
the changes in heating efficiency above and below the critical frequency
are apparent.
Below the critical frequency, efficiency drops rapidly because
less current is induced due to
current cancellation. Current cancellation becom
es significant when the reference depth is such that
eddy currents
induced from either side of a workpiece
"impinge" upon
each other
an
d,
being
of opposite
sign, cancel each
other.
For through heating, a frequency close to t
he critical frequency should be
chosen. In contrast, for shallow heating in a
large workpiece, a high frequency
is selected. This is the situation for surface
heat treatment of steels. In these
instances, there is no concern about critical
frequency because the workpiece
diameter will typically be many times the refe
rence depth.
10
10
m ~ z l
(.3
z n l
O
/
Q~
ii
-$
r~O.1
Y
X
/
O.O1t
1
10
100
1000
% of cr
itical
frequency
EQUIVALENTRESISTANCEAND EFFICIENCYOTHERGEOMETRIES
The expression given above for electrical effi
ciency 7/in terms of the induction-coil resistance and the resistance of the
workpiece as reflected in the coil
circuit, or equivalent resistance, is a general
one for all geometries. The major
difficulty in evaluating this expression lies in
the determination of the equivalent resistance Req.
Because Req is a func
tion of geometry, its value can be
estimated only for a limited number of particu
larly simple shapes. These are
(a) a short,
stubby round bar,
(b) a hollo
w tube,
and (c) a rectangular slab.
The equation for the equivalent resistance of
a short bar is identical to that
for a long bar except for a factor Ks2 (Fig
.
2.11): Req =
pTro~N2KR2KsJd w.
The Ks2 factor takes into account the "fring
ing" of the magnetic field at the
bar ends,
which becomes important
when
the
length-to-diameter ratio
becomes small. The expressions for a long, hol
low tube and a rectangular slab
are similar to
that for a long, solid bar e
xcept for
the definition of KR~, for
which the values shown in Fig. 2.12 and 2.13
are employed.
A type of workpiece which is being heated i
ncreasingly by induction nowadays is thin
sheet. In this case, two pan
cake-type inductors are used to
set
up
an alternating magnetic fieldperpendicular
to the sheet, rather than parallel to it, as it would be for a solenoid coi
l surrounding the sheet. Known as
transverse-flux induction heating, this method a
llows the use of less-expensive,
low-frequency power supplies in order to obtai
(2w
+ 2
e)p/t 2
where w,
t,
p, and t are sheet width, indu
ctor length, workpiece resistivity,
and sheet thickness, respectively. The accuracy o
f this equation was confirmed
in a series of low-carbon steel annealing tri
als using an inductor with an Rc
equal to
2.125 ft. Using an
average value
of p
over the temperature
range
through which the steel was heated for anneal
ing purposes,
a coil efficiency
~/of 83.5% was predicted. This compared favora
bly with the values between
83 and 86 obtained experimentally through measu
rements of the power into
the coil and the (known) heat
capacity o
f the
workpiece material.
Further
information on the design of transverse-flux indu
ction heating systems is given
in Chapter
6.
*S. L. Semiatin et al, "CMF Reports-Rapid An
nealing of Sheet Steels," Center for Metals
Fabrication, Columbus, Ohio,
1986.
----------------------- Page 23---------------------22
Elements
of
Induction
Heating:
Design,
Control,
and Applicati
ons
1.0
bl/l"
09
= 0
I
_.~....'-5,
0.8
~
~
bilL = 0.2
~
0 7 _~"~
f ~
o.o
~
0.5
o
--~
cs
0.4
O
~
o.3
0.2
0.1
0
0
0.4
0.5
0.6
0.1
0.7
a/b1
?
0.2
0.8
0.9
0.3
1,0
bl
D D D D D D D
t
'
t
Fig. 2.11.
Workpiece
shortnes
s
correction factor used for calculating
workpiece
resistance as reflected
in induction-coil circuit for short, solid
round bars (from C. A. Tudbury, Basi
cs of Induction Heating, Vol
1, John
F. Rider, Inc., New York,
1960)
For irregular geometries for which effici
ency calculations as described above
are not possible,
minimum
frequencie
s for efficient induction heating are chosen on the basis
of the
ratio
of
so
me characteristic dimension
of the
workpiece to the reference depth.
The
frequency is chosen to
obtain
a rat
io of at
----------------------- Page 24---------------------Theory of Induction Heating
23
3 . 4 -3 . 2 3 . 0 -
2 . 8 2 . 6 2 . 4 2.22.01.81.6n 1.41.21.00.80.60.40.2
oE
0
4
11
6
12
Ratio of
7
13
2
8
3
9
10
14
outside diameter to
reference depth
resistance
(a/d)
Fig. 2.12.
Workpiece
factor
used for calculating
workpiece
resistance as reflected in i
nduction-coil circuit for round, hollow loads
(from
C. A. Tudbury, Basicso
f InductionHeating,Vol
1, John F. Rider,
Inc., New York,
1960)
least 4 to
1 or at least 2 to
or parts
which are basically round
or flat, respectively.
1 f
DETERMINATION OF POWERREQUIREMENTS
As
Design,
Elements of Induct
Control, and Applications
1.1
f
1.0
0.9
0.8
,
0.7
o.6
-
0.5
J
/
,
I
0.4
I
I
i m
I:E
I/
t,
w , j
0.3
,j
/
I ~
I ~
"1
/ I
, -
i. o o o
o o
o
2pW
0.2
I
R 2 e q
= Ld2
KR2N1
2
0.1
o o o o e o o o o o
J
,-
I
I
I
0
7
Ratio of
thickness
istance
rkpiece
to
reference depth
Fig. 2.13.
factor
used for
resistance
in induction-coil
circuit
loads
(from C. A.
csof InductionHeating,Vol
(T/d)
Workpiece
calculating
res
wo
as reflected
for
rectangular
Tudbury,
Basi
1, John
F.
Rider,
Inc.,
ing.
New
York,
1960)
The amount
of power that
is needed for a given application is
also an
important
consideration.
If t
he
workpiece is regularly shaped
and
is to
be
through heated or melted,
the calculation is
straightforward.
However, if it
is to be only selectively heated so that the r
emainder of the workpiece is a heat
sink for the generated heat, calculation of the
power needed may be difficult.
The latter calculation is not
considered here; guidelines for surface heati
ng
for the
purpose
of surface heat tr
eatment
of steel are given in
Chapter
6.
For through-heating applications, the power
density should be kept relatively low to allow conduction from the outer
layers (which are heated more
rapidly by higher current densities) to the i
nner layers. There will always be
a temperature
gradient,
but
this
can be
minimized by
car
eful
selection of
induction heating parameters.
Neglecting the temperature
gradient, the absorbed power depends on the required temperature
rise AT, the total weight
to
be
heated per
unit
time W,
and
the
specific heat
of the
material
c. The
power
PI to be supplied to the load i
s then given by PI
=
WcAT.
of
Induction Heating
25
s in
d.
With proper
excess of 90%
designs,
are
coil efficiencie
readily obtaine
of
and
the
are
described
below.
27
----------------------- Page 28---------------------28
eating:
Elements of
Induction H
Design, Control, and Applications
Generator
Capacitor
Inductor
and
is
Resonant
capacitance
(in
farads).
Circuits
To understand
how power is stored or
dissipated in various
elements of a
series (or parallel) tank
circuit, it is
important to recognize the nature of the
voltage and
current passing
through
e
ach.
When
an ac voltage is impressed
across a resistance R, the voltage drop is
in phase with the current and is equal
to the product
of the current and the res
istance, VR =
IR. On the other hand,
inductors
and
capacitors
offer
a diffe
rent kind
of "opposition"
to current
flow, known
as inductive reactance XL an
d
capacitive reactance Xc,
respectively. They are defined as:
X
d
Xc
= 1/2rfC
where
is
L ~--
2xfL
an
frequency.
/(IV
I - I V c l ) +
I q ( X L -- X c ) 2
-4- R
E l e m e n t s o f In
Design,
Control,
and Appli
V L
= IX L
I
IVLI-
IVcf
V R =
V c
IR
IXc
V
R
(a)
(b)
Fig. 3.3. Vector
diagrams
illu
strating (a) phase relationships
between
current and voltage
in the variou
s components of an ac series LCR circuit and (b) relationship between t
he applied emf E and the voltage drops
across the
resistor
(VR), the
inductor
(VL), and the capacitor
(Vc)
in
such s circuit
(from C. A. Tudbu
ry, Basicsof InductionHeating,Vol 2,
John
F. Rider,
Inc., New York
, 1960)
True,
The
Reactive,
definitions
and
Apparent
of reactance and
Power
impedance
to
r
the
angle
between the current and voltage in an electri
cal circuit. For a tuned series circuit containing an inductor, a capacitor, and
a resistor, which appears to consist of a pure
resistance,
the current
and
voltage are in phase,
PR.=
0, and
the
power
factor
is equal
to
unity
. For
both
a pure
inductance and
a pure
capacitance,
the phase
angle is equa
l
to
90 , PT =
0, and the power
factor
----------------------- Page 31---------------------Tuning of Induction Heating Circuits and Load Matc
hing
31
1,0
L = lOOph
C = lOOppf
E=lOmv
0.9-0.8
R=10~
0.7-J
0.6
0.5-to
-E
0.4
0.3
~
R = 100~
0.2
0.90
0.95
1.00
1.10
1.05
to, 107/s
Fig. 3.4. Current
amplitude as a
function of frequency for an ac series
LCR circuit whose components
have
the values
indicated
(from
D. Halliday and
R.
Resnick, Physics,
Wiley, New York, 1966)
viewed across these elements alone
ero. Note also that low power
factors
correspond to
high
Parallel
Resonant
is equal to
values
of
z
Q.
Circuits
or
resonance
by
making
the
inductive r
eactance
equal
to
the
capacitive
Elements of Induction
Design, Control, and
Applications
- Q
L
E(t)(~
(
R
i
Fig. 3.5. A simple parallel
resona
nt
(tank)
arallel with
circuit
consisting of a
supply voltage
E and a capacitor in p
an inductor and a resistor
often
are
heating
employed
circuits
Heating
Circuits
and
or
at
directly as the
a lower
freq
frequency.
In view of
the
large
kV
AR
input
to
capacitors,
it is the
refore
important that they have high efficiencies. Acc
ordingly, most capacitors have
power
factors less than
0.0003.
Fig. 3.7.
Typical
ceramic capac
used to tune induction
heating circuits (source: Lindberg
Cycle-Dyn
itors
e, Inc.)
Elements of
Inducti
Design, Control, and Applications
Common
terminal
Cooling
water
Cab
les to
E
gen
erator
~,~_
x ~
9 ~Typical
,..~
rating
<
Collector
300 kVAR
10 kHz 460V
/I
140 mm
~ . .
(51/2in.) ~
I
(Cooling water
connections
not sh
own)
Fig. 3.8. Schematic illustration of
a capacitor bank used in tuning induction
heating
circuits for low
- and medium-frequency
induction
heating
power supplies (from C. A. Tudbur
y, Basicsof Induction Heating, Vol
2, John F. Rider,
Inc., New Y
ork, 1960)
The power
factor
of the
coil(s)
is generally low,
and
the
current
la
gs in
phase.
Because the capacitor is used to
co
rrect the power
factor to unity
,
it
must be capable
of drawing a leading c
urrent which is equal to
the lag
ging
component of the current drawn by the induct
ance. The capacitors operate
at rated output voltage and the resultant rea
ctive power (kVAR) of the capacitor must usually be
several times the
rated
kW
power
of the
supply.
The example shown in Fig. 3.9 will serve t
o illustrate the use of capacitors
in tuning. Consider the case in which the coil-he
ating power requirement (i.e.,
true
power)
is 200 kW.
Assume that
2000 kVA
are being
drawn
from
the
power
supply during the initial setup; thus
the power factor is only 0.1
of
1990 kVAa
66 kVAR
Cos = 0.95
Fig. 3.9. Vector diagram
illustrat
ing power-factor correction for a fixedfrequency induction heating power
supply
of 0.95 which is leading, an additional capac
itance of 200 tan(cos -1 0.95) =
66 kVAR
must
be utilized.
Thus,
the
total kVAR
requirement
would
be
1990 +
66
2056
kVA.
TRANSFORMERSAND IMPEDANCEMATCHING
Induction heating
sources have rated
current and voltage limits that
cannot be
exceeded without damage to the
source. The ratio
of the rated voltage to the rated
current is the effective
impedance of the
source. To
obtain
the greatest transfer
of energy from the
source to the load,
the impedances
of the two should be as close to each other as
possible. If they do not match,
transformers
are then
employed.
A transformer is a device consisting of two
coils (or windings) which have
"mutual" inductance between them (Fig. 3.10).
The primary winding is connected to the supply, and a voltage is induced
in the secondary winding, which
is separated from the primary by an iron c
ore or air core. A transformer can
be used to
increase (step up)
or decrease
(step down) voltages.
The relationship between the voltages in
the primary
(Ep) and
secondary
(Es) is determined by the ratio
of the
turns in each:
Ep
Np
Es
Ns
Here, Np and Ns denote the turns in the prima
ry and secondary, respectively.
The
current that
flows in the
secondary
winding as a result
of the induced
----------------------- Page 36----------------------
36
Elements of Induction
Design, Control,
and Applications
Heating:
I
P
Ep
0
0
O~
Es
i ~ R
>
0
0
N
N
P
S
Ep
principle
and
induction
heating
voltage must produce a flux which exactly equa
ls the primary flux. Because
the
flux is proportional
to the prod
uct
of the number
of turns
and
the cur-
Nsls
or
Np
Is
Ns
Ip
Hence,
and
vice versa.
It should be borne in mind, h
owever, that these equations apply
only to transformers with perfect coupling betw
een the primary and secondary
windings. In reality, coupling is not perfect,
and the voltage and current ratios
will each be
slightly less than the turns
ratio.
When a transformer is used for load-matchin
g purposes, the impedance of
the secondary is adjusted to match that of the
electrical load, and the primary
impedance matches that of the source.
Usually
, this involves reducing a highvoltage line supply to a lower-voltage, higher-c
urrent one. Because impedance
is equal
to
E/I,
the
impedance
ratio
between
the
primary
and
secondary
(Zp/Zs)
can be calculated by means
of the
equation:
Ze
N 2
Zs
Thus,
al to
o.
the impedance
the square
ratio
of the
is
turns
equ
rati
of Induction
Matching
Heating
Circuits
and
(a)
(b)
Fig. 3.11. Photographs of (a) an
autotransformer (source: Hunterdon
Transformer
Co.) and (b) rear vie
w of an isolation
transformer,
showing
adjustable taps (source: Jac
kson
Products
Co.)
When
a coil
coil
may
impedance
operate
is
very high,
directly across
the
output of the
power
supply (which is u
sually of high impedance).
Howeve
r,
a matching transformel
is frequently
used.
Matching transformers
for
lowand medium-frequency use generally have laminate
d iron cores. Where highimpedance
work
coils must be matched
to
the
system and thus
coil vol
tage
is high, tapped autotransformers* (Fig. 3.1 la)
are utilized. These transformers
have tapped
secondaries so that they can
be used to match coil impedance to
supply impedance.
Switches can be employ
38
Heating:
Design,
Elements of Induction
Control, and Applications
of Induction
Matching
Heating
Circuits
and
--0
XFR
q{
,
<
---o
c
<
<
---o
C1
C2
Ca
Coil
TIT
(a)
?) ?)?)
'"1
- Q
(
0
Coil
(b)
Fig. 3.13. Schematic
circuit
di
agrams of low- to medium-frequency heat
stations
illustrating capacitor
and transformer adjustments when
using
(a) an eutotransformer
(for hi
gh-impedance
induction coils)
end (b) an
iosolation transformer
(for low
-impedance
induction coils)
because
the
impedance
would
chan
ge
dramatically
if the
part
were
not
in
place.
Accordingly,
balancing
shoul
d
be performed
using
short,
low-p
ower
tests
so that minimal
heat
is produce
d
in the workpiece
during
setup
and
so
that
conditions
for comparison
ther
efore
remain
almost
static.
Metering
on
fkxed-frequency systems g
enerally consists of a kilowatt meter,
an ammeter,
a voltmeter,
and
a kV
AR
or power-factor
meter.
These m
eters
sometimes
are read
in percentages
of their maximum
ratings
to simplify
tuning. When
the system is tuned
prope
rly,
an
increase in the
output
of
the system
will reflect
increases
in both
current
and
voltage
simultaneously.
An
increase in one and
a decrease in the
other are indicative
of improper
b
alance.
During
the
actual
tuning
operation,
such as that
for a motor-generator
system,
the
field is slowly increased
s
o that
the
meters
begin
to indicate.
If the
power
factor is lagging,
capacitance mu
st
be added to
the tank
circuit.*
If the
*Note that this assumes a parallel
reson
ant tank circuit. If the power factor is laggin
g, the
lagging component of the current I 2 (in Fig. 3
.5) is too great,
and the leading component, or
the current through the capacitor, must be increa
sed. Because this leading component is equal
to E/Xc, Xc must be decreased.
Therefore,
the capacitance
must be increased.
----------------------- Page 40---------------------4 0
eating:
Design,
Elements of Induction
Control,
and Applications
power
factor
leads, capacitance
e removed.
The power
must
while changes are made in the
must
b
be off
capacitor
bank.
When
the
power
factor has
been
co
rrected
as close to unity as possible,
power
should be
increased until
either
the voltage or the
current reads the
maximum permissible.
Readings
of all
meters
should then be taken.
If, as
machine power is increased, the voltage reache
s a maximum before the current does, the primary-to-secondary ratio of the
transformer is too high. The
ratio must be adjusted,
or turns must be
removed from the work coil based
on the equation:
Required turns = present turns x
d at rated voltage/rated amperage
amperes obtaine
Should rated
current be
achieved before
rated
voltage,
the primary-to-secondary ratio is too low. The ratio must be
adjusted, or turns must be added
to the work
coil as follows:
Required turns = present turns x
oltage obtained at rated amperage
rated voltage/v
During
Heating
(Solid-State)
Circuits and
41
(solid-state)
power
Power
supplies
Lo
Sourc
gener
ate
frequencies which
are determined by the electrical characteristics of the t
ank-circuit components. Accordingly, as the inductance of the coil changes du
e to heating of the part
or loss
of permeability
above
the Curie temperature
,
the supply
frequency
shifts
accordingly. Tuning and load matching of such s
olid-state systems varies with
the
particular type of system,
which
is g
enerally one
of two
kinds:
(1) a
constant-current or load-resonant inverter, or
(2) a constant-voltage or sweptfrequency inverter.
Constant-Current(Load.Resonant)Inverter. Load-reso
nant inverters are essentially
variable-frequency power
supplies.
They h
ave no
resonant
circuit, but, by
means of a feedback system derived from the tank
circuit, they key the power
supply to operate at the tank-circuit frequen
cy. This in effect allows them to
vary in frequency as the resonant
tank
d
oes when the
coil/part
impedance
shifts during heating. Accordingly, once the tank
circuit is tuned to within the
allowable frequency range of the generator, the
generator frequency shifts to
match the tank
frequency. It is therefore
said to be "load resonant."
Parallel-tuned circuits, as used
in load
-resonant generators,
are not selfstarting inasmuch as they depend on an increa
se in load voltage to cut off the
SCR's to start oscillation. Therefore, a piggyb
ack or "pony" inverter is usually included in the generator design to initiat
e oscillation. To ensure that the
system will start, it is standard procedure t
o connect all the available capacitance to the system when beginning, providing th
42
ting:
Design,
Elements of
Induction
Control, and Applications
the same
as that outlined
for tuning
fixed-frequency
motor-generator
systems.
Hea
of
oscillator.
Radio-Frequency(Vacuum-Tube)Power Supplies
High-frequency, vacuum-tube power supplies a
lso make use of a tank circuit for the transfer of energy to the workpi
ece (Fig. 3.14). In this case, however, the circuit generally contains
a tank
coil in addition to the induction
heating coil. As a workpiece is heated and i
ts reflected resistance increases,
the tank current IT tends to decrease. However
, the vacuum tube supplies an
additional current Ip to make up
for the lo
sses and thus to keep the tank current constant.
The plate ammeter of the r
adio-frequency (RF)
supply reads
this current Ip.
Under a "no-load" condition (no part
i
n the work coil), the plate current
Ip I represents the minimum current supplied
to the tank to replace the losses
dissipated
by the resistance Rp
associated
with
the unloaded
tank circuit.
When the load is placed in the work coil, a
"full-load" plate-current reading
IP2 indicates the new plate current required
to
supply not
only the losses in
Rp but also the additional losses of the loa
d represented by R L. Accordingly,
the losses in the
load are directly related
to the difference between the
two
readings,
I L = IP2 - Ipl. Obviously,
the
difference between
the full-load
reading and the no-load reading represents t
he load current required by coupling of energy into the load
or workpiece
. Therefore, that
combination of
transformer or load-coil tap adjustments that
produces the greatest differential
between
readings
represents
the best imp
edance
match
between
the work
coil/part and the generator tank.
----------------------- Page 43---------------------Tuning of Induction Heating
Load M a t c h i n g
43
Circuits
and
I
T
Ep
I S
R
~,,-~, X c
B
I
Rp
R L
on
of
gs
The
tap
with
no
the greatest
load
and
readin
difference between
full load
is the
ost
appropriate connection for the system.
selected for a coil/part
ination,
it will always be the same.
same approach
is also used
Once
comb
The
in se
lection
of the
appropriate
primary-to-secon
dary ratio
if
an RF
power
out
put
transformer
is used to
connect the coil
to
the power
supply.
Because the difference between no load and
full load is proportional to the
power into the part, it is important to try to
maintain as low a no-load reading
as possible.
Generally the no-load reading
should be
at most
30 to
40%
of
the
maximum
allowable
plate
curre
nt.
However,
the
physical
constrain
ts
of the
coil generally
dictate
this
co
ndition.
When
a high
no-load
read
ing
occurs, the number
of coil turns
can
be increased
or the transformer
t
urns
ratio
can be decreased.
In performing the tuning procedure it is
best to use reduced power.
H
owever, once the
power
level is set,
i
t should not be
changed during this test.
Further,
the
grid
adjustment
for th
ese
conditions
should be
maintained
in
accordance with machine specifications. Once tu
ning has been accomplished,
the system should be run
at full power
to
determine actual heating-rate and
plate-current
readings.
When certain loads such as small copper
parts are being heated, it is often
found that
there is very
little differe
nce between
the
no-load
and
full-l
oad
readings.
This is due to the fact that
the resistivity of the material is low.
It
may
also be
physically impractical to
add
more
turns
to the
coil. In
these
cases,
it is sometimes practical
to u
tilize
a poor
impedance match
so a
s to
increase the current in the work coil. Under
these conditions, the no-load cur----------------------- Page 44---------------------44
ating:
Design,
Elements of Induction He
Control, and Applications
F).
The
loading
coil, in series with t
he
work
coil, presents
a high impedance to
the generator,
at the low tempera*This is based on the fact that each incr
ement of three turns will increase the load cur
rent
b y l A .
----------------------- Page 45---------------------Tuning of
Induction
ad Matching
4 5
Heating
Circuits
and
)urce
)er shunt
Lo
"ated
Fig. 3.15. Use of an auxiliary
in
ductance ("series loading coil") to assist
in tank-circuit tuning in heating
of steel workpieces below,
through,
and
above the Curie temperature
(from F. W. Curtis, High Frequency
Induction Heating, McGraw-Hill,
New York,
1950)
ture,
so that
full power is supplied to the
coil. Above the Curie temperature,
the shorting bar eliminates the loading coil. I
t is important
that the power be
off during the brief period when the solenoi
d is activated to
short the lo
ading coil.
----------------------- Page 46---------------------Elements of Induction Heating
Copyright 198
8 ASM International
Stanley Zinn, Lee Semiatin, p 47-75
All rights reserved.
DOI: 10.1361/eoih1988p0047
www.a
sminternational.org
Chapter 4
Induction
Heating
Power Supplies
orkpiece,
important
ment
s frepower
this
power
fac-
Fig.
presently
4.1.
available
are
summarized
FREQUENCYAND POWERSELECTIONCRITERIA
4 7
----------------------- Page 47---------------------48
Heating:
Design,
1000MW
Below
10
Joining
100MW
Elements of Induction
Control, and Applications
Melting,vessel heating
I~ Forging, forming, etc. ~
mm diam
i
~Above 100 mm diam
"~
10to 100mm
~'Large (f
J
Above
1.25to
Below
30 mm
mm
1.25mm
~,
2.5
f Special processes-
Skindepths
10MW
Tube welding
Crystal growin
g,
~ /
Triple
zonerefining
rs
/
o
0_
1 MW
.
100kW
~
P P Y - e q ~ i T , ~ ~ i i
/ , ~ q u e n c y s y s t e m s
su
systems
~
~
~ ~ k ~ k
~
~
in$etltd;sta2ed
motor-alternators
10kW
lW
10Hz
10kHz
100Hz
100kHz
1kHz
1MHz
10MH
z
F
requency
Fig. 4.1. Ranges of power ratings an
d frequencies for induction gen-
erators (from J.
Davies and P. Simp
son, induction Heating Handbook,
McGraw-Hill, Ltd, London, 1979)
lowest possible frequency that will accomplis
h the job
is usually the best sele
ction from an economic viewpoint.
Typ
ical frequency selections
for a number
of specific
applications
are summarized i
n
Chapter
6.
Power
requirements for induction heating
are also
dependent
on the sp
ecific application.
In through-heating
applications,
the power
needed is gen
erally based
on the
amount
of materi
al that
is processed
per unit time,
the
peak temperature, and the material's heat capac
ity at this temperature. Power
specification
for other operations,
s
uch as surface hardening of steel, is not
as simple because of the effects of startin
g material condition
and heat con
duction to the unhardened core. Nevertheless,
guidelines in such situations are
available
(Chapter 6).
When guidelines
for
ents,
such as those in
power
requirem
Chapters 2 and
th
Heating
Power
Supplies
49
ally transferred
into the
workpiece and no
t
necessarily to the
power drawn
from the power
supply. Power losses are o
f three
forms:
Coupling losses between the coil and the w
orkpiece. As discussed in Chapter 2, the percentage of the power
supp
lied to the coil that is transferred
to
the workpiece is a function
of the
resistivity and
permeability
of the
workpiece material, the coil geometry, and t
he distance between the workpiece and the coil.
Power losses between the output terminals
of the power supply and the coil.
These losses are associated with improper
tuning of, and I2R losses in, the
appropriate tank circuit, imperfect impedance
matching between the power
supply and the workpiece/induction coil, a
nd transmission losses between
the
power
supply and the induction coil.
Power losses within the power
conversion of line frequency
to higher-frequency ac.
supply due to
It should
also be emphasized that
the
method
of rating power
level for
induction power supplies varies. For example,
motor-generators are rated in
kilowatts
(rated
current times rated volta
ge times power
factor)
at the output
terminals of the generator.
Because s
olid-state power
supplies were initiaUy direct replacements for motor-generators,
manufacturers have continued
this rating practice. Therefore,
power outp
ut
and efficiency ratings of solidstate inverters relate to power supplied at
Heating:
Design,
- -
- -
Elements of
Control,
and A
Thermometers
Heating coil
u
_ . .
/
.-2AAAA
2 _
A
I n
Out
Fig.4.2.
Calorimeter use
dto determine the power output of a radiofrequency (RF) power supply by
measuringwater
flow and temperature change (from F. W.
Curt
is, High FrequencyInduction Heating,
McGraw-Hill, New York, 1950)
supplies, let
lass, because
generic c
from part
system to
to part
and
from
system. However,
it is safe to
assume
that
line-to-load efficiencies for low- and
medium-frequency solid-state systems generally run between 60 and 65%
and that those for
RF (vacuum-tube)
generators typically range
from
50 to
55%.
With this as an introduction, the design
and characteristics of each of the
various types
of power
sup
plies are discussed next.
TYPES
Line-Frequency
eating
OF
POWER
SUPPLIES
Induction
Heating
Power
Supplies
51
GENERATOR
T RUN
HEA
DATA
STATION
STATION 2
Function:
HR4
HR1
HR1
HR2
HR3
HR2
HR3
HR4
Plate Voltage
KV
DC
Plate Current
AMPS
DC
Grid Current
AMPS
DC
Filament Volts
V AC
Load Inlet Temperature
F
Load Outlet Temperature
o F
Load Flow
GPM
KW Output
KW
Frequency
HZ
Enclosure Temperature
F
Generator
Inlet Flow
GPM
Generator
Flow Temp
In
F
Generator
Temperature
Valve Setting
F
"Load
Reference Mark"
Line Voltage
Line Current
GENERATOR "NO
LOAD"
DATA
Plate Voltage
KV DC
Plate Current
AMPS
DC
Grid Current
AMPS
DC
Frequency
HZ
Line Voltage
V AC
Line Current
AMPS
AC
TESTED
BY:
DATE:
Elementsof InductionHeating
:Design,Control,
and Applications
contactor
2_
.___Main
I
JII(.
Power-factor-
3_
correctioncapacitors
Tapswitches
Transformer
primaries
I~_Ioooopooooo
o o-o0 o#o-0o o oo-o-tYo'O~1
~nR~O0000-O000-O-O'~Secondaries]
r
L,.p_o00000O000000~,J
~ooooop_ooooo_o.ooooJL~o
ooooooo~zo.p.ooooojJCoil---(a)
(
Capacitors
----I(
. ~coarse~ ~ J 44fine
l
I(
L ' ~
~
3
Secondaries
Coil
(b)
Heating
Power
Supplies
53
Fig. 4.5. Tap switch used in adjust
ing voltage on the primary
of a linefrequency
induction
heating sys
tem
(source: American
Induction
Heating Corp.)
fitting operation.
Having
a high-input
impedance,
and
operating at
110
or
220 V, this application requires no power-fac
tor correction. Essentially composed of a primary winding and a laminated co
re structure (Fig. 4.8), the system utilizes the bearing as a shorted second
ary. Several laminated blocks are
employed to control the flux path through the
core and the center of the bearing (Fig.
4.9). In addition, a set of mov
able blocks is supplied with the equipment to
enable it to fit a range of be
arings.
When the bearing
size matche
s
the transformer core opening, the bearing i
tself may be used to close the gap
in the core.
On a somewhat larger power level, the same
technique is used
for heating
ferrous or nonferrous rings,
such as
locomotive tires
(Fig. 4.10).
Typically
a
75-kVA, 440-V, single-phase unit is used to
heat titanium rings varying from
31 to
152 cm
(12 to 60 in.) in diamete
r by up
to 10 cm (4 in.)
in cross
section to
760
C
(1400
F) in
1 to
5 min.
for
a stretch-forming application.
Because of the requirement for opening and clo
sing of the transformer core,
this type
of system is often referred to
as a "split-yoke" design.
In another nonferrous application, line-fre
quency heaters are used to
heat
aluminum, copper, or brass billets prior to
extrusion. The billets are carried
on motor-driven rolls (Fig.
4.11) and are h
eated in three-phase, line-frequency
Design,
Elements of Induction
Control, and Applications
6000 kW.
Line-frequency systems are also util
ized in dual-frequency heating
lines for forging. The depth of penetration
for steel below the Curie temperature is considerably less than
that above it.
Therefore, the minimum diameter of
steel billet that
can be heated
efficiently at
60 Hz
is approximately
6 cm (2.4 in.)
at temperatures below 705
C (1300
F).
Probably the largest induction heating insta
llation, line-frequency or otherwise, is the slab-heating facility illustrated in
Fig. 4.13. It is rated at a total of
210 MW.
Six heating lines each with three hea
ting stations are used to preheat
600 tons of steel per hour transported
from a storage yard or directly from
a continuous caster.
Slabs as large as 30
cm (12 in.) thick by
152 cm (60 in.)
wide by 793 cm (312 in.) long are heated t
o
1260 C (2300
F)
for rolli
ng.
The slabs, which may weigh as much as 30 tons ea
ch, are heated in coils which
encompass their longest dimension (Fig. 4.14) rat
her than being wound across
their width. Efficiency is optimized in this m
anner, because flux-field cancellation across the long dimension is less than
if the coil were wound conventionally.
----------------------- Page 54---------------------Induction
Heating
Power
Supplies
5 5
' -
Self-lubricating
Bel
lows
bearing
Get
ter
oviog
contact
II
eld
Shi
"
- q . k '~--L
Arc-control
material
~
~
J ~
Fixed contact
= :
= ,
al ends
-1
Met
Pro
tective
Evacuation tube
~
met
al cap
Cold welded
seal-off
Fig.4.7.
Vacuum and air break
contactors usedfor line-frequencyinduction
heating (from J. Davies a
nd P. Simpson, InductionHeatingHand-
book, McGraw-Hill,
Ltd.,
London, 1979)
Frequency
Multipliers
Elements of Inductio
Design, Control, and Applications
Core
(a)
(b)
Fig. 4.8. Laminated core and primar
y winding for an induction unit used
to expand bearings: (a) "split-yoke"
system and (b) production bearing
heater (from C. A. Tudbury, Basi
cs of Induction Heating, Vol 2, John
F. Rider,
Inc., New York, 1988;
Read Electric
Sales
and
Supply)
The
180-Hz
as a tripler
ctly
from
60-Hz
current,
is
dire
compose
of three
saturable
reactors,
each
of
which is connected between one leg of a Y-con
nected secondary and a singlephase load. The voltages from the secondarie
s are
120 apart.
Passin
g them
----------------------- Page 56---------------------Induction
Heating
Power
Supplies
57
I
I;]V/,Ird~
V,,,J
W
Small
b
bore)
t
pillar
d
be hea
r
size o
larges
t yoke.
For flanges with large outside
ould the workpiece
have a very
Sh
Large
sm
horiz
p
the l
can
be used.
For long pieces, the working
space can be incr
eased by using a pair of support
yokes,
Combi
nations of various yokes may
or the space can be raised by combining
suitab
le yokes in a vertical position.
be us
ed for workpieces with stepped
bores
, such as couplings,
Fig. 4.9.
Adjustment
care structure for heating
laminated
that
pulleys, etc.
the flux
of the
bear-
Industries,
Inc.)
through
a single-phase
output,
therefore,
produces
three p
ulses
in the
same
time period as that in which a normal 60-Hz
system would produce one waveform.
Accordingly,
the frequency
is essentially tripled.
Th
e
180-Hz system is
similar
to
the
60-Hz
heater
in that
the
circuit
containing
the
load
must
be
tuned
to
the
frequency
of
th
e power
supply-namely,
1
80
Hz.
Systems
ne frequency,
such
as
may
540
be cascaded to produce
other multiples of the
li
Hz.
Motor-Generators
A
motor-generator
is a rota
ry-driven system composed
of a motor
coupled
to
a generator.
The motor
and the
generator
can be individua
l units with
a
----------------------- Page 57---------------------5 8
n Heating:
tions
Design,
Elements
Control,
of
and
Inductio
Applica
duction
American
In
Heating
Power
Supplies
5 9
Fig. 4.12. Line-frequency
ind
uction
system
used to
heat 15-by-15-by115-cm (6-by-6-by-45-in.)
rou
nd-cornered
square steel billets for forging of
(source: American
Corp.)
diesel-engine
Induction
crankshaft
Heating
Fig. 4.13.
One stage of the Mc
Louth steel
induction
slab
heating facility, rated
at a total of 210
MW,
used to
preheat
slabs as large
as
in.
30 cm by 152 cm by
8
m (12
by 60 in. by 26 ft) to the roiling
tem
perature
of
1260
(2300
F)
(source: Ajax
Magnethermic
Corp.)
slots of the
stator, there are two windi
ngs.* One,
called the
field wind
ing, is
connected to
an external source of direct
current and
forms a magnetic
field
around the rotor.
When the rotor rota
tes,
alternating currents are induced
in
the
second,
or output,
winding.
These
currents
result
from
changes
in the
magnetic flux in the slots (where the stator
windings are located) as the rotor
sweeps past
them.
*Formally,whenboth sets of windings (field and
output) are on the stator, the equipment
is calledan inductor-alternator. Somemotor-generat
orshave the output windingson the rotor,
rather than on the stator.
----------------------- Page 59---------------------60
Heating:
Elements of Induction
Design, Control, and Applications
Steel slab
heating
f
10 kHz is considered to be the practical limit
for rotary equipment of this sort.
The output voltage from a motor-generator
is a single-phase voltage generally of 200,
400,
or 800 V. This outpu
t
voltage is adjusted by controlling
the voltage to
the field winding. Because th
e output
voltage has a tendency
to
decrease
automatic
ften
as the
voltage
load
increases,
regulators
are
Heating
Power
Supplies
61
tor set
motor-genera
Design,
Elements
Control, and
of Induction
Applications
lation
transformer
for impedance matching
(Fig. 4.18).
When
an isolation
transformer is used, the capacitors are connect
ed in parallel with the primary.
The transformer primary is tapped to provide a
range of voltage adjustments.
When an autotransformer is used (with high-impe
dance coils) the capacitors
are
generally
connected
in parallel
w
ith
the
work
coil.
With
very-highimpedance
coils, it is sometimes
possi
ble
to match
the generator
output
impedance without the use of an intermediate tran
sformer.
In either case, provision is made to add or subtract capacitanc
e for proper
frequency matching.
It should be noted, though, that
since p
ower-factor correction makes use of
discrete values of capacitance, it is not gene
rally possible to tune the system
exactly to the resonant frequency of the moto
r-generator.
Because of this, it
is generally advantageous to adjust the power
factor initially so that
it is i
n
Fig. 4.17. Heat station
for use at
low and medium frequencies with
an impedance-matchingtransformer (sou
rce:American Induction Heating Corp.)
----------------------- Page 62---------------------Induction
63
--0
XFR
,c
,(
-0
~
--0
Coil
(a)
'"I
- Q
0
0
XFR
(b)
Fig. 4.18. Schematic
circuit dia
grams
of a
low-to-medium-frequency
heat station
illustrating
capaci
tor and impedance-matching adjustments
when
using (a) an autotransfermer
for high-impedance induction
coils
and (b) an isolation transformer
for low-impedance
induction
coils
a
a
-
Such
wholly com
pensate
for decreases (more
common)
or
increases
(less common)
in t
ank
inductance during heating.
However, ope
rating for any period in the lagging
condition can cause excessive field current with
associated field relay tripping.
Solid-State
Inverters
Heating:
Elements of Inductio
Design, Control, and Applica
Load-circuit
characteristic
Internal
\
commutating
components
~ ~
I-----1
Series r
eactr
Power c
ontrol
by fre
quency
Fixedvari
ation
dc supply
Variablefrequency
T
L--
T---f
local oscillator
Inverter
Load c
ircuit
(a)
Frequency
Load-circuit
Operating
frequency
Commutating effe
ct
characte~_j
and inverte
r
timing derive
d
from load circ
uit
t
I
g
nt-current
I// ~/I Powercon
trolby
reactor
III
_L_
ill
c voltage
Inverter
- T
g
Variable-voltage
/~'
i ~
f 'x
V~r'fa~quneatcY
dc supply
Load
circuit
(b)
Frequency
y
Fig. 4.19.
Circuit
schematics
for (a) a swept-frequency inverter and (b)
a load-resonant or constant-curren
t
solid-state inverter (from J. Davies
and P. Simpson, InductionHeating H
andbook,McGraw-Hill, Ltd.,
London, 1979)
oscillator whose output signal then controls t
he inverter firing rate. The system
then operates at a frequency along the straigh
t portion of the tank's resonantfrequency curve, but not
at the r
esonant
frequency.
By offsetting the
firing
rate
of the
oscillator
from the resona
nt
frequency of the tank,
th
e unit
can
be made to operate at any point along this
Heating
Power
Supplies
65
oltage capacitors
for tuning.
Further, since the inductance of the transmission
line becomes part
of the tank
inductance, the distance from the power supply
to the work coil is limited for
reasons
of efficiency.
Figure 4.20 compares the relative over-all e
fficiencies of motor-generators,
swept-frequency inverters, and load-resonant inv
erters. The low efficiency of
the motor-generator is due to the high inertia of
the rotor, windage losses, and
similar problems
produced by the
mechanica
l system. These must be
overcome, even for the lightest loads,
since the
generator must always operate at
rated
speed regardless
of output
power.
The
low efficiency of
the sweptfrequency inverter at light loads is due to the
fact that it is operating at a low
point
on the resonant-frequency curve.
Because solid-state inverters were initially
designed to replace motor-gen----------------------- Page 65---------------------66
tion
Heating:
lications
Elements
Design,
Control,
of Induc
and App
100
90
d-resonant
80
70
>~
O
~~aLoa
60-
~itrlralternator
(1)
"G
W
5040-3 0 - I
I
40
i
60
80
20
100
Output powercon
stantloadimpedance,%
over-all
motor-generator,
a swept-fre
quency
inverter,
and
a load-resonant
(constant-current)
inverter (f
rom J. Davies
and
P.
Simpson, Induction
Heating Handbook, McGraw-Hill,
Ltd., London, 1979)
erators,
the power
ratings
of these
systems were based
on
standard m
otorgenerator
rating techniques-that
is, power
is rated
at the terminals
of the
generator, neglecting the losses in the heat s
tation, coil, etc. For this same reason, power-supply frequencies were also chosen
to match those of available
motor-generator sets to reduce confusion. Howe
ver,
solid-state power-supp
ly
frequencies
are
really
not
limited
because
the
generators
are
eith
er
loadresonant or controlled by a local oscillator.
Thus, a frequency can be selected
which is optimum for the application. In eff
ect, all solid-state generators are
actually variable-frequency inverters. For a spe
cific piece of equipment, apparent power
at the terminals will vary wi
th
frequency. Therefore,
pow
er
supplies
generally
are
designed to
o
perate
within
a
specific
frequency
range.
Further, heat-station capacitors must have suf
ficient kilovar capacity to
handle the
frequency range used,
and
magnetic components (transformers
and
reactors)
must be rated
for operatio
n
at these
frequencies as
well.
----------------------- Page 66---------------------Induction
Heating
Power
Supplies
67
Spark-Gap
Converters
Although no longer produced commercially, the
spark-gap converter was
one of the earliest means of providing high-fre
quency ac power in the radiofrequency region. It was used primarily in metal
melting, in particular for precious metals.
In its simplest form (Fig. 4.21), the spar
k-gap converter includes a step-up
transformer
(T0
which increases the lin
low--on
oad.
the
order
15 to
5070 line-to-l
Radio-Frequency
(Vacuum-Tube)
Power
Supplies
Operational
Characteristics.
The operation o
f a radio-frequency (RF) power supply is best understood with reference to the par
allel resonant tank circuit con0
A
012
Low-frequenCYinput~.E1
Sparkgap ,_j
0
Secondaryworkcoil
Primar
I
0
1
ouuo
0
v
Fig. 4.21. Simplified circuit diagra
m for a spark-gap induction generator (from Induction Heating, American
Society for Metals, Metals Park,
OH, 1946)
----------------------- Page 67---------------------68
ating:
Design,
Elements of Induction He
Control, and Applications
filament
plate.
It is the
the tube in syn-
chronization
with
the
oscillating volta
ge
in the tank
so that
it acts
as t
he
switch. The tank-circuit oscillation is sustain
ed by providing makeup power
from the dc supply, through the tube at th
e resonant
frequency of the tank.
A small amount of the total tank voltage,
180 out of phase with it, must be
supplied
ain this
voltage"
Heating
Power
Supplies
Flat caused
by
grid drawing
current
V
q5
.8
Linear
portion
C
of curve
- 2
0
-8
-6
0
J
] Currentflows
No plate current
Class A
all the time
flowing
I Current flows
Class B
lessthan
-4
is
positive
C
1
Twice
cut off
Fig. 4.23. Relationship of plate c
urrent to grid current
in an oscillator
operated
under "class C" conditi
ons (from V. Valkenburgh, Basic
Elec.
trenics, Vol 2, Hayden Book Comp
any, Inc.,
Rochelle
Park,
NJ, 1955)
In an actual oscillator circuit (Fig. 4.24
), the dc power supply is connected
to the tube circuit with the positive lead in the
tube plate circuit via choke LA
and the negative lead connected to the filament.
The tank circuit is in parallel
with the tube; blocking capacitor CA passes t
he RF current, but blocks the
dc from the tank.
The tank inductance is
composed of the tank
coil L
and
the
work
coil Lw.
A
magnetically cou
pled tickler
coil LG couples energy
from the tank coil to the grid and filament of
the tube via the grid capacitor
CG and
a grid resistor RG. This
resisto
r keeps the average potential of the
grid in proper relation to the filament for
class C operation.
Methods
of developing the grid
feedback signal vary
from
oscillato
r to
oscillator. In induction heating power supplies,
standard oscillators are the
inductively coupled tickler-coil system (Fig.
4.25a),
the
Hartley
osci
llator
(Fig. 4.25b), and the Colpitts oscillator (Fig.
4.25c). With the latter two systems, the feedback voltage is automatically contr
olled as a percentage of the
tank voltage, either by the transformer tap rati
o (Hartley oscillator) or by the
----------------------- Page 69---------------------70
ating:
Elementsof Induction
Control,
and Applications
Design,
He
High-voltagedc
Choke @
coil
LA
Bl
ockingcapacitor
C
A J
I
I
~
L
~
.__~ LGI
A n o d e / ~
I
(
~
Work
-L
Tank
C G
Filamen . ~
R ~ r i d
Lw
, i, capac'tor
Workcoil
Filament
-heating
transf
ormer
60 Hzac
Fig.4.24. Circuit diagramfor a simpl
e vacuum-tube-typehigh-frequency
generator (from Induction Heating, Am
erican Society for Metals, Metals Park, OH, 1946)
ratio of grid tank
capacitance to plate tan
k capacitance (Colpitts
oscillator).
With the tickler-coil technique, the coil is m
echanically adjusted
in relation
to
and, therefore,
coil to ground.
arcing
from
Design
Considerations.
Most
common RF g
enerators oscillate in the range of
200 to 450 kHz.
It is apparent
that as
the coil inductance changes, the resonant
frequency of the tank will vary as wel
l. Thus, unless crystal controlled
----------------------- Page 70---------------------Induction
Heating
Power
Supplies
71
dc anode
C
supply
p b
O .
. .
C
9
(a)
!
E
C
C
pb
pb
m
(b)
-(c)
"~
"
its
n
Fig. 4.25.
Oscillator circu
in
high-frequency
inductio
used
genera-
b) Hartley,
Davies and
tors:
(a) grid
and (c) Colpitts
P.
Simpson,
Handbook, McGraw-Hill,
d.,
London,
1979)
coupled,
(from
(
J.
Induction Heating
Lt
Elements of Induct
Design, Control, and Applications
=10A
p
l
3_
N L
(a)
g
N
= 30 turns
P
Work coil
=
3 t u r n s
= 3 turns
L
t
Work c
oil
I
= 1 0 0 A
L
(b)
Ip
= 10 A
Fig. 4.26.
Output tank circuit
s of common high-frequency induction generators:
(a) direct tank loa
ded
and {b) transformer
coupled
(as in sputtering systems), the frequency will sh
ift within the above limits during operation.
Unlike the motor-generat
or,
which tends to hold the
voltage
constant, the RF generator tries to maintain
a constant circulating current in
the tank
circuit.
Although all RF power supply ratings are
in terms of "power into a calorimetric
load,"
they will not
neces
sarily all respond
similarly to
a particular
coil/part combination. A power rating refers t
o the capability of an individual
system to supply the rated power to this load
. It does not refer to the ease with
which it can deliver that power.
Typically, if the supply can deliver
10 kW to
the test load with a 2.5-cm (1-in.) coupling
Heating
Power
Supplies
73
siderable. If an RF output transformer is used
and is outside the power-supply
enclosure,
or
if a low-impedance heating
coil is used
at a distance
from
a
DTL-connected generator,
significant
power
losses will occur.
In general,
a
coil or transformer remote from an RF genera
Design,
Elements of
Control,
and
Fig. 4.28.
Multitapped
Induction
Application
feedback tr
ansformer that
provides adjustable
grid drive when the tank circuit is
located remote from the power supply
(source: Lindberg Cycle-Dyne, I
nc.)
supply enclosure. The primary is connected betwee
n the plate of the tube and
the tube filament to derive a frequency signal
. A secondary winding provides
a voltage which is
180 out
of phase
to
drive the grid.
Radio-Frequency
(Solid-State)
Equipment
of
kHz
operating
System
a
www.as
minternational.org
Chapter 5
Auxiliary
Induction
Equipment for
Heating
re
What
is the maximum temperatu
any component can tolerate?
2. How much water
flow is nec
remove the heat
from the syste
that
essary to
m?
veloped to
red
the
by
Each
of these
inspecting the
questions is answe
specifications of
77
----------------------- Page 76---------------------78
Heating:
Design,
Elements of Induction
Control, and Applications
olts
above ground,
yet must be cooled with
water.
To
accomplish this,
water
is
carried to the tube through a length of nonc
onductive hose, passed through
the tube cooling channel, and then returned t
o ground through a similar hose
column. In essence, this hose column is a
high-resistivity path with water
as
the conductor. At a
10-kV level, approxim
ately 5 m (16 ft) of hose must be
used on each side of the column to provide a
sufficient length of water path
to prevent
the
water
from
carrying
current
and
thus
dissipating additional
heat.
This presupposes that
the resis
tivity of the water
is sufficiently high.
Another consideration in a water-cooling sy
stem regards the regulation of
the water temperature to
a level abov
e the
dew point
in the area
or
cab
inet
where the system operates. A temperature below
this point will result in condensation
on
the cooled
components.
Condensation,
particularly
in hi
ghvoltage areas,
can cause arcing between com
ponents of differing voltages and
the resultant
failure
of these
componen
ts.
In addition,
any technique that
reduces water consumption will provide an econom
ic means of cutting water
and
sewage costs.
In perhaps the simplest type of cooling s
ystem (Fig.
5.1), water is passed
from
tank,
through
pump,
to
the
induction heater,
with
the
return
path
going
back
to the
pump.
Raw
wate
r
from
the
tap
is passed
through
a
temperature-control valve whose sensor is in the
output waterline of the generator.
Because additional tap water is added
to the system, an overflow pipe
passes the excess to
a drain.
In operation, cooling water is added to th
e system from the tap as the exit
water temperature exceeds its limits. Thus,
tap water is added only on temperature demand, reducing input
ents. This system also main-
water
requirem
Motor
. Pump
Generator
[
~
~ _ ~
Thermalcontrol
Inlet
t
l~lrr I
Wa
ter
Outlet
I~,/)
nlet
"~
F --r"
'
settingflow
Overfl
Tank (95to 380 L, or
Z
!
Stopcockfor
Sightdrain
Fig. 5.1.
'
25to 100gal)
Simple water-cooling syst
Equipment for
Induction
Heating
79
Systems
overheat.
Table
5.1
covers a typical
s
pecification for water
quality for
an
induction heating generator. Solids-content limits
in parts per million are generally considered for cases in which constant fl
ow brings contaminants into
the system on a continuous basis. However, onc
e the system is sealed, additional solids are not brought into the cooler,
and the tap water becomes similar to distilled water.
When the
cooling system is used in a
plant
where temperatures may go
below freezing for any period of time, the cool
ant should be composed of a
mixture of water and ethylene glycol to preve
nt freeze-up. A 40%
solution
of ethylene glycol is satisfactory in most local
ities. It should be noted, however, that most antifreeze solutions, although t
hey are ethylene glycol based,
should not be used. Unlike pure ethylene gly
col, the additives in antifreeze
reduce the resistivity of the coolant and thus cau
se problems in hose columns.
Table 5.1. Typical
cooling-water
specificati
on for an induction heating power
supply
(source:AmericanInductionHeatingCorp.)
Minimum pressure differential, 2
07 kPa (30 psi)
Maximum inlet water temperature,
35 C (95 F)
pH between 7.0 and 9.0 (i.e.,
slightly alkaline)
Chloride content < 20 ppm
Nitrate content <
10 ppm
Sulfate content <
100 ppm
CaCO3 content < 250 ppm
Total dissolved solids content <
250 ppm;
no solids to precipitate
at T
_
57 C (135 F)
Design,
Elements of Induction
Control, and Applications
Systems
ping
station,
they
offer
a method
of
reducing water
consumption.
Typically, vapor-cooled systems (Fig.
5.2) utilize a mist of water
spraye
d
onto the fins of an air-to-water heat exchan
ger. This water is lost as a vapor
or mist of steam, but because of the high h
eat input per unit weight of water,
the
system requires
only about
17o
of the normal water usage
of a conve
nInlet
Cooled-liquid outlet
\
Pump recirculates water
Centrifugal
blowers force
from
reservoir pan at
a high volume of air upward
bottom to distribution
over coils
trough at top.
Fig. 5.2. Schematic illustration of
the operation of a vapor-cooled heatexchanger system (source: Water Save
r
Systems, Inc.)
----------------------- Page 79---------------------Auxiliary
Equipment for
Induction
Heating
81
tional water-cooling system. The
isolates the equipment coolant
system
still
Air in
Evaporative
Vent
cooler
valvesat
Drain
high
points
Pumpi
ng
stat
ion
Optional /
ndoorsSUmp'i tank
Equipment
Fig. 5.3. Vapor-cooled heat-exchange
r system with a pumping station
adjacent to the power-supplyequipmen
t (source:Water Saver Systems,
Inc.)
----------------------- Page 80---------------------82
Heating:
tions
Design,
Elements
Control,
of Induction
and
Applica
Drain in
winter
Drain
Fill
Air in
Pumping
station
l
Vents
Equipment
Fig. 5.4. Vapor-cooled heat-exchange
r system equipped with a recuperator that returns waste heat to th
e plant air-circulation system (source:
Water
Saver Systems,
Inc.)
----------------------- Page 81---------------------Auxiliary
Equipment for
Induction
Heating
83
power
supply. The control signal is compared
with a prescribed, or setpoint,
value, and the difference is fed into the fe
edback circuit.
Systems of this sort
are described in Chapter 7. By contrast,
o
pen-loop systems are not nearly as
sophisticated, relying primarily
on measure
ments of heating time to
ensure
reproducible and accurate results. For
appl
ications in which process param-
Design,
Elements of Inductio
Control, and Applications
o oscillatorkey
valve gridCa ac,,or
b
ias resistors
I
Fig. 5.5. Circuit
schematic for
a grid-trigger
system used for high-speed
operation of an RF power supply (
from J. Davies and P. Simpson, Induc.
tion Heating
Handbook, McGraw-Hil
l,
Ltd., London, 1979)
kept
energized.
System timing is then
produced by
a "grid-trigger"
device
(Fig. 5.5) that applies a negative bias to the
grid of the tube, driving it to cutoff. This makes the grid of the tube highly
negative and thus prevents current flow from cathode to anode. A very light r
elay-contact closure is all that
is necessary to short the bias voltage through
a shunt resistor, restoring the
normal grid bias.
The speed of control
of the system is limited only by the
operational speed of the relay, because the tub
e is operative at the resonant
frequency of the tank.
----------------------- Page 83---------------------Elements of Induction Heating
Design,
Elements of Induction H
Control, and Applications
F r o m Chapter
2, the reference
depth
is given by
d (in.) =
3160
pv~/~f whe
n
the
resistivity
p is in units
of
O-in.,
or
d (cm)
=
5000
pvr~#f when
p
is in
fl-cm.
For
round
bars,
the
critical f
requency
is that frequency
at which
bar
diameter
is approximately
four
times
reference
depth;
for slabs
and
shee
ts,
the critical
frequency is that
at which
thickness
is about
2.25 times reference
depth.
For
these
simple geometries,
the critical
or m i n i m u m frequency
f is
therefore
given by
(a
in
f~ =
in.) / Round
f~ =
(a
in
cm)
1.6 x
bar
108 p/i.ta
10 8p/#a 2
o r
'L
fc =
(a
(a
in
in
in.) [
cm)
Slab
fc =
5.06
107 p / # a
or sheet
1.27
x 108 p / # a 2
where
a is bar diameter
thickness.
The
critical-frequency
are most
readily evaluated
or
slab/sheet
expressions
for nonmag-
netic materials,
or those
for which/z
=
1. In these cases,
fc is simply a
f
unction
of
geometry
and
the
material's
resistivity.
Values
of
resistivity
p
for
various
metals
are given in
Table
6.
1. It can be
seen that
p is not constan
t,
but
varies with temperature.
For
this
reason,
estimates of fc are usually based
on
the value
of p corresponding
to t
he peak
temperature
to which the
me
tal
is to be
induction
heated.
To
illustrate,
critical
frequency
w
ill be
calculated
for
several
situatio
ns.
Consider
first the heating
of a 1.91-cm
- (0.75-in.-)
diam round
bar of alu
min u m
to 510
C (950
F).
From
Tab
le
6.1, the resistivity
at this temperat
ure
is approximately
10.44
10 -6 fl-cm
(4.1
x
10 -6 l]-in.). Because
#
=
1, the
equation
for critical frequency
yields
fc =
1170 Hz.
If the bar were made
of
an
austenitic
stainless steel, on the
ot
her hand,
the resistivity at the same te
mperature
would
be approximately
10
1.6 x
10 -6 l]-cm
(40
10 -6 ~].in.),
and
the
critical
frequency
would
be
app
roximately
ten
times
as great,
name
ly
11,380 Hz.
For
the case
of magnetic
steels, t
he
above
equations
for
fc apply
as
well.
However,
~ is a function
of temperatur
e.
Below the
Curie temperature,
# -100 for typical
power
densities.
Above
this temperature,/~
=
1. If the
round
bar in the above
example
were
of a
carbon
steel that was
to be tempered,
it
would
have
a resistivity
of about
63.5
x
10-6
O.cm
(25
x
10-6
fl.
in.).
Assuming #
=
100, the critical frequency
would thus be 71 Hz.
If this bar
were
heated to
a higher temperature,
say
980
C (1800
F), at which/~ -1 an
d p
=
----------------------- Page 85---------------------Process Design for Specific Applications
87
k~
' , . o e ~
~q
,,4
~q
5e4
.
.
.
.
.
.
.
e ~
"
P"."P"..
.
.
.
.
o
o
o
~i~5
~q
.~-
,,4
,,4
5,
qrc
~
~
,,4
, ~
,,4
~
,~o
~o~
2
I ' r ~.
~
0 ~ , " ~
I
,.4
~i.~;
~
o.;
|
v " ~ O 0
~ ' 1 0
~rC
~ q
, ' - ~ e q
, . . ~ e q
.
.
.
.
.
. o
.
.
.
.
.
~
.
.
~N
.
.
~ r 0
.
.
.
.
.
.
.
.
.
.
~
.
. ~
.
.
.
~
.
.
.
.
.
.
.
.
.
.
.
.
.
.
~
.
~
. ~
. . . .
. =
.~,
: ~ , ~
o
~
.
. ~ g o .
tD
----------------------- Page 86---------------------8 8
eating:
Design,
Elements of Induction
Control,
and Applications
117
x 10-6
fl.cm
(46 x
10-6 fl.in.), t
he critical frequency would increase
substantially to
approximately
13,000 Hz.
Variable-frequency power
supplies typ
ically offer a twofold
or threefold
range of frequency. Thus,
for nonmagnetic m
aterials, the same generator can
be used to heat parts of a given size over a
and
thus
the induced
current are lower
.
Because the
current
through
the
induction
coil and
its resistance
remain
fixed,
the coil
dissipates a given
amount of power. However, the amount of energy
dissipated in the workpiece
decreases with poorer coupling. Therefore, the p
ercentage of the total energy
which is used to heat the workpiece decreases
, and efficiency goes down. A
similar argument can be used to explain the low
efficiency associated with the
heating of a tube using a solenoid coil loca
ted within the tube.
In this
case,
the field strength is small outside the coil t
urns,
and relatively small amounts
of current can be induced in the workpiece. Th
e coupling in these situations
is low even when the air gap between the coil
and workpiece is small. Thus,
this type of heating arrangement should be av
oided unless space limitations
or other considerations demand it.
Charts
of the efficiency of heating of
tube
and pipe products
using
solenoid coils located around the outer diameter
provide useful information on
the influence of workpiece geometry.
Important
factors here are
the outer
diameter
and
wall
thickness
of the
tu
be
or pipe. Several useful
plots for
medium-carbon
steel products
heated
either below
the
Curie
temperature
(such as may be required for through tempering
) or above it (such as in nor----------------------- Page 87---------------------Process Design for Specific Applications
8 9
J
O O
O
O
O
O O
O
O O
.
O
O O
O O
O O
~
O
O
.=
.=
s ~
=
m
==-.-|
J~
~o
,m
~o
~
q~.
..4=
m
Design,
Elements
Control,
of Inducti
and Applic
Diameter, mm
5.1
0
12.7
19.1
1,000,000
7.6
1.3
2.5
25
38
3.8
51
500,000
200,000
\
\
100,000
N
-r
c50,000
cr
\
20,000
\
10,000
\
\
5000
\
3000
Diameter,
in.
heating
(from F. W. Curtis, Hi
gh FrequencyInduction Heating, McGrawHill, New York,
1950)
malizing or hardening operations) are depict
ed in Fig. 6.3. From these curves
it is apparent
that,
for a given power
-supply frequency and
tube
geo
metry
(OD,
ID),
the efficiency is higher for h
eating below the
Curie temperatur
e.
This is a result of the
smaller reference
depth below the Curie temperature.
Similarly, the increase in efficiency with incre
ased frequency for a given geometry and temperature range are associated w
ith higher OD-to-d ratios
as for
the induction heating
of solid bars.
Two
other trends
are not
so o b
v i o u s those related to the effects of outer diame
ter and wall thickness for a given
----------------------- Page 89---------------------Process
Design for
Specific Applications
91
Round-bar diameter, mm
6
102
279
305
127
152
178
100
90
0
203
25
229
51
254
80
5,
t'.~_
,b
~
70
6C
i e
r ,g
5c
OF)
o
ie
O F)
4C
3(
2(
0
3
11
4
12
1
8
2
10
Coil efficiency
or
c-
induction
of air gap
and
induc-
heating
tion
between
of
round bars
of
bar
as a fun
diameter, size
coil
and bar,
tion
quency:
180
Hz
power-supply
Hz and
1 kHz;
(a) 60
and
3
G.
F. Bobert,
Systems
kHz; (c) 10
"Innovative
fre
(b)
kHz
(fro
Induction
of
Elements of
Design, Control,
Induc
and
R
ound-bar diameter,
mm
0
102
305
127
152
178
203
25
51
229
76
254
100
279
u
3 kHz
180 Hz
B/C
I ~
-
~
"
B/C
80
A/C
G
"~
60
__
(up to
705
cI urle .
C
or
1300 F)
I/
B,c
A/C
Be,ow
50
= Above
Curie
(over 705
i
40
Coil
or
1300 F)
~
ID = bar OD
= 38
mm
(1.5
in.)
= 51
mm
(2.0
in.)
30
C
= 64
mm
(2.5
in.
)
D
= 89
mm
(3.5
127 mm
in.)
(5.0
in.
)
20
I[
[
0
1
10
3
11
2
R
ound-bar diameter,
in.
(b)
F
ig.
be
g.
6.2. continued
inferred
from
2.12.
Hence,
down
with
decreasing wall thickness.
the
data
in
efficiency goes
Fi
For
th
Design for
Specific Applications
93
R
ound-bar diameter,
4
31.8
38.1 44.5
mm
0
50.8
6.4
57.2
76.2
82.6
100
-mmmmmm
90
80
C
7'
10 kHz A/C
70
>~
O
c
/
E~
.-
60
(9
B/C
= Below Curie
r o
5o
(up to 705 C or
1300 F)-
~ / ~
A/C
= Above
Curie
(over 705 C or
1
1300 F)
40
~ '
I
CoillD
A
=barOD+
= 38 mm
A
(1.5 in.)
B = 51
mm
B
(2.0 in.)
30
C = 64 mm
D = 76 mm
(2.5 in.)
c
I
(3.0 in.)
2O
0
.0
3.0
1.25
3.25
1.50
Round-bar diameter,
1.75
0.25
0.50
0.75 1
2.0 2.25
2.50
2.75
in.
(c)
F
ig. 6.2.
continued
is two
orders
of
magnitude
l
ess
than
that
required
if a
sol
enoid
coil
is
employed. The ability to use a much lower
frequency impacts
heating costs
in two
ways.
First,
the
higher-freq
uency
(RF)
power
supply that
would be
----------------------- Page 92---------------------94
ction
Heating:
plications
Elements
Design,
Control,
of Indu
and Ap
1.0
0.9
magnetic(belowCurie)
60 Hz,
0.8
0
0
~
0 . 7
- -
0.60
0.50
0.6~
0.40
;.=
0.5-0.4-0.30
0.3~
0.20
0 2 t l
0.1
0 1
0.10
I ~ 5
2
3 4
I
8
10
24
t2
14
16
18
20
22
Out
erdiameterin inches
1.0
0.9-0.8-nmagnetic(aboveCurie)
60 Hz, no
0.7-0.30
0.6-E
0.20
U
0.5-0.10
uJ
0.4 ;-0.05
(5.3i--
o
0.60
Note: Numberson
0 . 2 - 0.50
curves indicat
e
0.40
thicknessof wa
ll
0.1
in inches.
0
10
12
1 2
t6
14
3 4
18
6
20
8
22
24
Ou
terdiameterin inches
(a)
induction
f
ameter
f
Hz {from
using
wall thickness
power-supply
and outer
frequencies
di
o
1
0.70
\
Curves for 0.
60 to 0.70wall
,
1 0 . 5 0 ~
0.9
/
thic
kness only
0.710.40
0.70
0.30 ~ "
o>" 0.8
. ~ > ,
\
O
o.6-
j
t .Q-)
/
!
2 0 7
os-
I
0.60
LU
0.4
-- 0.
0.6
10
12
Outer diam
eter in inches
0'3--0:
No
te:Numberson
0.2
curves indicate
/
Y0.05
!hickness of wall
0.1 -in inches.
I
I
I
I
10
22
I
I
I
01
I
I
12
24
14
2 3 4
16
6
18
20
=~
(above Curie)
0.8--
3\
"G
~=
J
0.7
0.6
020
0.5 -- 070
0.10
,T,
0.4
0.3
tubers on
- .
f//NSu
0.2 -H /
/
curves indicate
0160X//
/
!hickness of wall
0.1
1
8
0
10
22
12
14
Outer
24
diameter
in
inches
(b)
Fig.
6.3.
continued
3
16
6
18
Elements of
Design,
Control,
In
and
1 . 0 m
0 . 9 , magnetic (below Curie)
0 . 8 -
960 Hz
0.20 to 0.70
0 . 7 r
O
C
0 . 6 o
~z
0 . 5 -
UJ
0.4-0.3--
/
0.025
Note: Numbers on
0.2-curves ind
icate
thickness
of wall
0.1-in inches.
0
I
t/i
I
3.0
7
1.0
5
2.0
6
Outer
diameter in inches
0.9
0.8
nonmagnetic (above Curie)
960 Hz,
,f
0.20
0.7
O
C
0.6
O
0.5
LU
0.4
0.3
0.2
0.1
0
3.0
7
1.0
5
2.0
6
considered
Selection of Power
Rating for Throug
h Heating
During
selection
of
power
rating
for
induction
through
heating,
two
factors- material throughput
a
nd required temperature uniformity-should
be evaluated. The first of these, material t
hroughput,
determines th
e over-all
power rating because:
Required power = (kilograms/hour throughput)
x (kilowatt hours/kilogram)
x (efficiency fact
or)
----------------------- Page 95---------------------Process
Design
for
Specific
Applications
97
The factor "kilowatt hours/kilogram" is known a
s the heat content; it is the
amount of thermal energy required to heat a giv
en material usually from room
temperature
to a higher,
specified
temperature.
As might be
expected, the
value of heat
content
increases wit
h the temperature
to which th
e metal
is
heated. Heat contents for a number of materia
ls are summarized in Fig. 6.6.
Tables 6.3 and 6.4 also provide related infor
mation-i.e.,
typical
processing
temperatures
for several metals and th
e heat
contents
of these me
tals when
raised to these temperatures.
The efficiency factor in the simple equation u
sed to calculate power requirements is determined by the coupling efficienc
y of the coil to the workpiece
(that is to say, the percentage of the energy s
upplied to the coil that is transThickness,
mm
0.254
2.54
25.4
254.0
105
104
N
T
0
cO"
.=
0
t_
L)
103
102
0.01
0.1
1.0
10
Thickness,
in.
Fig. 6.4.
Critical
frequency
as a function of sheet thickness for several
different
metals
induction
heated
using
a solenoid
coil (from G
. H.
Brown, C. N.
Hoyler,
and R
. A.
Bierwirth,
Theoryand Application of
Radio FrequencyHeating, Van
Nos
trand,
New York,
1947)
----------------------- Page 96---------------------9 8
Elements
Design,
Induction Heating:
trol, and Applications
Thickness,
of
Con
in.
0.004
0.039
394-
0.
;.94
I
I
I
3000
1000
N
1"
u
t"-1
0"
i,
200
50
I
I
I
0.1
1.0
10
100
Thickness, mm
Fig. 6.5.
Relationship betwe
en
required generator
frequency and sheet
thickness for transverse-flux
induction
heating
of aluminu
m
and ferritic steel
alloys
(from
R. Waggott,
et el., Metals
Technol
ogy, Vol
9,
December,
1982,
p 493
)
ferred to the workpiece) and by thermal loss
es due to radiation and convection.
These factors were discussed in Cha
pter 2.
Requirements on temperature uniformity mus
t also be considered in selection of power rating. Temperature uniformity duri
ng through heating is influenced, however, by both
po
wer-supply
frequency
and
power
density.
Low
frequencies enhance uniformity by providing larg
e reference depths, or depths
of current penetration. For this reason,
frequencies as close as poss
ible to the
critical frequency should be selected. Lower
frequencies lead to low heating
efficiencies. Use of high
fre
quencies is more
expensive from
an
equipment
standpoint
and mandates the use of
soaking time after the heating cycle to
allow for heat conduction from the shallow-h
eated zone to enable temperature
equalization.
Power density, or power per unit of su
rface area, has
a similar effect on
----------------------- Page 97---------------------Process
ns
Design
for
Specific
Applicatio
99
temperature
uniformity.
y
high power
densities
to
over-
Excessivel
may lead
heating
(or even melting)
of
the
workpiece
surface.
Moderate
power
densities allow moderate
heating of the
workpiece
surface and sufficient t
ime
for
the heat to be conducted to the center of
the workpiece.
The variat
ions
of the
surface and center temperatures
of an induction heated round bar are depicted
schematically
in Fig.
6.7.
At
the
beginning
of heating,
the
surfa
ce
temperature increases
much
more
rapidly
than the temperature
at the
center.
After
a while,
the rates of increase
of
the surface and center temperatures
become
comparable due to
conduction.
However,
a fixed temperature
di
fferential persists during heating.
The
allowable
temperature
differential permits
the generator power rating to be selected. The basi
c steps in selection of power rating
for
heating
of round
bar are
as
follows:
Select
the
frequency
and
ca
lculate
the
ratio
of
bar
diameter
to
reference
depth (a/d).
As mentioned above, the
frequency for through heating should
T
emperature, C
0
538
649
93
204
760
316
871
982
427
10
93
1204
0.11
~
).242
0.10
).22
0.09
Aluminum
Nickel
0.198
0.08
, / ~ /
/
S t ~ T i t a n i u m
0.176
J3
0.07
f
0.154
=.-7:
0.06
c
G)
c
0,05
~
/
~
0.110
O
(.1
o)
I
0.04
0.088
-~
0.03
~
~
Copper (brass below 870oc or 1600oF)
0.066
I
I
0.02
-
Z
~
Gld (leadbelw315 C r 600F)-
0044
0.01
~
0.022
0
1000
0
200
1200 1400
400
1600
600
800
1800 2000 220
0
Temperature, F
Fig. 6.6. Heat content
(i.e.,
heat capacity) above 20 C (70 F) et several
of temperature
i, John
F.
different
metals as a function
(from C. A. Tadbary, Basics
of Induction Heating, Vol
Rider,
Inc., New York,
1960
)
----------------------- Page 98---------------------100
s of
Induction
Design,
pplications
Element
Heating:
Control,
and
B
=
.|
o
~L
|
I~, Fi
0
.=_
z
i)
~
~.=
,1~
1:)
K I
. ~
= ~
~,)
1-~
.=
e .
----------------------- Page 99---------------------Process
Design
A p p l i c a t i o n s
f o r
Specific
1 0
1
._~
~ u ' - ~ O
. 0
.~'~
~
~
. C . i
m
==
',"~
i
'I
===~=
n
i
' ~ ec'a
"1
e'~
-"~
'"~.
I
:~
=~ een
:e
; e
Ii
,.
C.,I ,,--q O0
E
=
| e ~ l
t ' ~ 'N 0
i | !
o o o o o o o
,!
.~L
"~
===='.
/~
~
/ ~
" ~ ' ~
'~
~ "
~=~I
~ . s
/
/
= I ~ /
.I
~,,a
. o o
~ o o
o
~
--- ~ .
' ~
" -
"~L
~ /
/
" = ' = ~
.
. .
.
" - " '
' ~ "
I_ i
*
- = = ~ /
>'
ai
,=
,, /
=
!
i
='-'-=,~=='
i ~ !
!
!~
==
-~
I~
/
=.,==/
' ' = ' '
"=
i .
~
tit
. +
I
i:~ 0 i
l
~
I=
"
~I
~ o
t
I::;
A
I i
iI~
,,
,,i /
/
...E "8
" ~
,=:
=
"~
= .o ~
Elements of Induction
Design, Control, and Applications
I
Heating
~(
Cooling
I
"-z
E
F/
r
Time
J"
Powe
at the
a /d ratio
corresponding to
the critic
al
frequency.
To illustrate the above procedure,
consider the through heating of a steel
bar
152 mm
(6 in.) long by
102 mm
(4 in.) in diameter to
a surface tempe
rature
of 980
C
(1800
F)
and
a
center temperature
of
870
C
(160
0
F).
Selecting a 540-Hz generator, the a/d
ratio is found to be approximately four.
----------------------- Page 101---------------------P r o c e s s D e s i g n for S p e c i f i c
p p l i c a t i o n s
103
Temperature, o C
427
982
538
1093
6.0 0
93
649
204
760
316
871
0.43
1
~
/
I
_
Copper
5.0
-_
Gold
0.36
/
"u-
4.0
0.28
o.
E
E
>~
.>_
~
3.0
- -
0.21
"10
t"10
t O
0
Titanium
O
o
O
f-
2.0
0.14
t -
l-Nickel
Steel (low C)
- j
0.07
Steel (1.0 C)
Stainless
steel
- -
_
Ol
I
I
I
I
I
I
I
I
200
1200
400
1400
600
1600
I
1
0
1000
2000
800
1800
Temperature, F
ctivity
on
ury,
k,
Fig. 6.8.
several
of
of
tem-
Thermal
metals as
condu
a functi
perature
(from C. A.
Basicsof InductionHeating,Vol
1, John
F. Rider,
Inc.,
New
1960)
Tudb
Yor
C (0.016 W/in.-F.)
Thus, the power required is (0.00113)(110)(152
)
=
19 kW.
This
to
a
corresponds
power
density (power per
unit
of
surface area)
of
19/(152)
(102)7r
=
0.00039 kW/mm 2 (0.25 kW/in.2).
If the temperature differential we
re to be
cut by a factor of two, the power rating and
the power density would be similarly decreased. There is, however, a lower
limit to which the power can be
decreased. This is determined by the heating ti
me itself. The heating timeis
equal to the amount of energy needed divided b
y the rate of energy input, or
power. For the above example, the workpiece w
eighs approximately 9.66 kg
(21.3 lb), which, using data
from Fig. 6.6,
requires (21.3)(0.082)
-1.75 kilo----------------------- Page 102---------------------104
uction
Heating:
d Applications
Elements
of
Design,
Control,
Ind
an
watt
hours
to heat to
925
C (1
700
F).
Therefore the heating time w
ill be
either
328
s (for
a surface-to-center
temperature
differential of
110 C,
or
200
F) or 656 s (for a temperature
differential of 55 C,
or
100 F) when
the
power rating is halved.
In actual induction through-heating operati
ons, power densities somewhat
higher than those suggested by calculations su
ch as the ones above are often
used
when a soak
or
dwell period p
recedes
forming,
quench hard
ening,
or
another operation. As suggested by the schemati
c illustration in Fig. 6.7, tem0.15
0.0107
0.14
" ~ "
1.0099
0.13
~ '
).0092
o.12
0.oo85
0.11
- -
0.0078
\
o
, ,
o.1o
o.oo
~
Th( ,rmal conductivit
F:
._=
F)
~
0.09
~'~
0.0064
~
(k), W/mm
E
~
(W/in.
'
h.....=
0.43
(6.0)
0.08
~
I
0.0057
~
0.36 (
5.0)
0.07
0.005
==
\
~ , . . =
~.
0.06
~
(4.0)-
0.28
0.0043
O
O
=
. _
~
=
"o
0.05
0.0036
--
' "
(3.0)
"o
- - ~
,,,-----
0.04
0.21
~
0.0028
0.03
~
2.0)_
~
1.0021
0.14 (
0.02
'
=
1.0014
~
7 (1.0)
0.0
=======,=
0.01
,
0.04
(0.5)
0.0007
0
o
0
12
10
4
14
6
16
18
8
20
22
Diameter/r
eference depth (a/d)
Fig. 6.9.
Induction thermal
factor for round bars as a function of ratio
of bar diameter to reference
depth (a/d) and thermal conductivity
(from
C. A. Tudbury,
Basics of Ind
uctionHeating, Vol
1, John
F. Rider,
Inc.,
New York,
1960)
----------------------- Page 103---------------------Process Design for Specific
Applications
105
Table 6.5. Approximate power densiti
es required for through
heating of steel(a) (from T. H. Spe
ncer, et al.,
Induction
Hardening and
s Park, OH, 1964)
Tempering, ASM,
Metal
Power
density(c),
kW/in.Z(d), for
[
heating
o
C
to
F)
to
temperatures
throug
of: - - I
150 to
425 t
760 to
980 to
1095 to
425 C
760
980 C
1095 C
1205 C
Frequency
(300 to
(800
(1400 to
(1800 to
(2000
to
Hz(b)
800 F)
1400
1800 F)
2000 F)
2200 F)
60 . . . . . 0.06
0.15
(e)
(e)
(e)
180 . . . . . 0.05
0.14
(e)
(e)
(e)
1,000 . . . . . 0.04
0.12
0.5
1.0
1.4
3,000 . . . . . 0.03
0.10
0.4
0.55
0.7
10,000 . . . . . 0.02
0.08
0.3
0.45
0.55
(a) For hardening, tempering, and
forming operations. (b) Powerdensity values in this table are bas
ed on use of proper frequency and
normal
over-all operating
effici
ency of equipment. (c) In general,
these power densities are for sectio
n sizesof 1.27to 5.08 cm (1/2 to
2 in.). Higher inputs can be used fo
r smaller section sizes, and lower
inputs may be required for large
r
section sizes. (d)
1 kW/in. 2
=
0.155 kW/cm2. (e) Not recommended fo
r these temperatures.
perature uniformity is enhanced during this
period as a result of heat conduction
and radiation
effects. After the
power
is turned
off, the hotter
s
urface
cools as it loses heat to
the
center (
by conduction)
and to
the
surroundi
ngs
(by radiation).
In contrast,
the cente
r temperature continues to rise because
of heat
conduction
from
the
surface.
Calculations of temperature uniformity as
presented above can be avoided
by reference to tables
of power
dens
ities ordinarily used
for through heat
ing
of various
metals.
One
such listing,
for through
heating
of magnetic
steels,
is shown in Table
6.5.
The values
of power
in Table
6.5 are based
on
typical efficiencies and
proper
selection
of
frequency (which lead to
a / d
ratios
usually in the range of four to
six).
Large-diameter bars,
which can be hea
ted
efficiently with low-cost, low-frequency power
supplies, typically employ low
power
densities.
This is because of the
longer times required
for conduct
ion
of heat to the centers of these larger pi
eces.
(It should also be
kept
in
mind
that
the reference depth increases above the
Curie temperature,
at whic
h the
relative magnetic permeability drops to unity,
sometimes necessitating higherfrequency units
for heating to high temp
eratures. An exception to this practice
is the use of 60-Hz
sources for inducti
on heating
of very large parts
such as
slabs
in steel mills.)
DESIGN
EATING
PROCEDURES
FOR
HEAT
TR
Hardening
Surface hardening
of
steel part
consists
Some typical
steels are:
induction
su
e of the part
and the case depth
needed. Shallow cases require high frequencies an
d power densities, and deep
cases require lower frequencies and power densi
ties. The principal difference
between hardening of steels and hardening of c
ast irons lies in the need to control temperature more closely for the latter mater
ials. For steels, the austenitizing temperature
can be varied over a fairl
y wide range without measurably
affecting the hardening characteristics, provide
d that long soaking times and
austenite grain growth are avoided. In contras
t, temperature control is very
*S. L. Semiatin and D. E. Stutz, Induction
Treatment of Steel, ASM, Metals Park,
OH, 1986.
Heat
Design for
Specific
Applications
107
important for cast irons because the carbon
ntent of the austenite phase for
a given alloy increases with temperature.
co
Starting
Material
Condition.
The star
ting material condition can have a marked
effect
on
response
to
induction
hardening.
The
Ac3
or Accm tem
perature
increases with
coarseness of microstruc
ture
as well as with heating
rate,
as
shown in Fig.
6.10 for
1042 steel. I
n particular,
at a given heating rate
, higher
austenitizing
heating,C/s
28
56
278
2778
2000
556
111
1111
1093
I
J
1900
1038
1800
982
O
LL
o
o
1700
927
. 0)
e~
J
ized
E
E
j
~
Q
o)
1600
J
871
I--
I..--" "
~
"
Quenched
and
~
tempered
""=
1500
816
Ae 3
1400
760
50
500
5000
Rate of
heating,
100
1000
200
2000
F/s
Fig. 6.10.
Effect
of
initia
l microstructure and heating rate on Ac3 temperature for 1042 steel (from W
. J. Feuerstein and W. K. Smith, Trans.
ASM, Vol 46,
1954,
p 1270
)
----------------------- Page 106---------------------108
Heating:
Design,
Elements of Induction
Control, and Applica
tions
Distanceb
elowsurface, mm
S
0.5
1.5
1.0
2.0
2.5
70
60
1
Quenchedand
50
tempered
o
nI
40
t'" 0
30
L
Normalized
I
Annealed
20
10
0
S
04
0.02
0.06
0.
0.08
0.10
Distanc
ebelowsurface, in.
Design
for
Specific
Applications
109
iron, also often known as ductile iron) remai
ns essentially unchanged during
heat treatment.
As another example, in
nodular cast irons which have been
previously quenched and tempered, the carbon
in the matrix
is in
the form
of many fine nodules. When this microstructure is
induction heated to hardening temperatures,
the carbon dissolves
and diffuses rapidly,
enabling quick
austenitization and excellent hardening response
.
Austenitizing
Temperature.
The time requ
ired to form a totally austenitic microstructure in a steel depends on the austenitizi
ng temperature selected and the
starting microstructure. In all cases, the speed
with which austenite is formed
is controlled by the diffusion of carbon,
a process which can be accelerate
d
a great deal by increasing temperature.
For example, the time for complet
e
austenitization in a plain carbon steel of eutect
(1380
f
80
730 C
60
f <
40
(1345 F)
20
1
10
1O0
1000
Time, s
Fig. 6.12. Effect of aaatenitizi
n9 temperature en rate of austenite formation
from pearlite in a eut
ectoid
steel
(from G. A. Roberts and R. F.
Mehl,
Trans.ASM, Vol 31,
1943, p. 613)
----------------------- Page 108---------------------1 10
eating:
Design,
Elements of Induction H
Control, and Applications
as
those used
Because the
in
only
s
exceeded,
ion
the
continuous-heating transformat
temperature
(Ac3 or Accm)
is
always above
the
equilibrium
one.
This
difference increases with heating
rate, as might be
e x p e c t e d - a n effe
ct shown in Fig. 6.10 for the A c 3 temperature
for
1042 carbon
steel. Here,
the
Ac3 temperature is the one at which it
has
been
estimated
that the
austenite
reaction
is complete.
As
pointed
out
above,
these data
also show that
the
increase in transformation
temperature
depends
on the
initial microstructure.
The
fine quenched-and-tempered,
or
martensitic,
microstructure revealed the
least change in Ac3 temperature
as
compared with the equilibrium Ae3 temperature,
whereas the
same steel with
an
annealed
the largest
microstructure
difference in
exhibited
Ac 3 as
com
pared
with
the
Ae3
obtained
with
v
ery
low
heating
rates.
Such
a trend
is
readily explained by the
fact that
the
diffusion
distance
to
redistribute
c
arbon
is shorter in the
former instance and
longer in the latter microstructure,
in which
carbides
are much
larger.
Based on data
such as those in Fig.
6.10,
guidelines have been derived for
required
austenitizing temperatures
f
or induction hardening of a wide range
of steels (Table 6.6).
Generally, these te
6.6.
Recommended induction
temperatures
for
and alloy steels(a)
au
Carbon
Temperature for
Temperature for
content,
furnace
heating,
induction
heating,
70
F (C)
F (C)
0.30
... 1550 to
1600 (845 to
870)
1650 to
1700 (900 to 925)
0.35 ..
1525 to
1575 (830 to
855)
1650 (900)
0.40..
1525to
1575 (830 to
855)
1600 to
1650 (870 to 900)
0.45 ..
1475to
1550 (800 to
845)
1600 to
1650 (870 to 900)
0.50 ..
1475 to
1500 (800 to
845)
1600 (870)
0.60 ..
1475to
1550 (800 to
845)
1550 to
1600 (845 to
870)
>0.60
..
1450 to
1510 (790 to
820)
1500 to
1550 (815 to
845)
(a) Free-machiningand alloy grades ar
e readily induction hardened. Alloy
steels containing carbide-forming elemen
ts (e.g., niobium, titanium, vanadium, chromium,
molybdenum,, and tung
sten) should be austenitized at
temperatures at least 55 to
100 C
(100 to
180 F) higher than those indicated.
Design
for
Specific Applications
1 1 1
70
60
o
tr
-1-
50
40
~_
I
I
o Alloy steels
Plain carbon steels
3o
20
II
0
0.20
0.80
1.60
1.00
0.40
1.20
0.60
1.40
C
arbon content,
case
hardness are both important.
Figure
6.14 illustrates case-depth selection for
a situation
involving torsional
fat
igue.
The
drawing
shows
two
dif
ferent
induction case-hardness patterns,
eac
h with a surface hardness of 52 HRC
and
a core hardness
of
12 HRC.
Assumin
g no
stress concentrators, the
a
pplied
stress is shown as a straight line from zer
o at the center to a maximum stress
corresponding to
52 HRC
at the su
rface. Case A provides a region in which
the applied stresses exceed the yield streng
th; on the other hand,
case
B has
----------------------- Page 110---------------------1 12
n
Heating:
pplications
a
Design,
Elements of Inductio
Control, and A
50
120
(827)
~
100
(689)
40
u}
Case depth
"~
" 0
80
c
o~
.C:
(552)
30
C~
r~
"O
Case depth A
60
(414)
20
> ,
tO
40
10
(276)
O
I-/
Applied
2O
(138)
0
30
10
40
20
50
40
Surface
Center
B
ar diameter position, %
Fig. 6.14.
Method of determining
induction case-hardnesspattern for
shafts subjected to torsional loadi
ng (from G. A. Fett, Metal Progress,
Vol
127,
No. 2,
February, 1985,
p 49)
----------------------- Page 111---------------------Process Design for Specific
Applications
1
1 3
Table 6.7. Relationship between
hardness and tensile
and torsional
strengths for h
ardened steels
(from G. A.
Fett, Metal Progress, Vol
1
27,
No. 2,
February,
1985,
p 49)
l - Strength,
le
ate
MPa
(ksi)
I
Hardness
I
Tensile
Torsional
Rockwell C
Brinell
yield
yield
52
60)
1613(234)
514.
1524(221)
917
40
85)
(140)
110)
(95)
(75)
interior
idual
ultim
1793 (2
965 (140)
50
45)
Tensi
1151(167)
30
841 (122)
20
614
(89)
10
503
(73)
0
365
(53)
689
503
365
303
221
481.
(133)
371.
(100)
286.
(73)
226.
(53)
187.
(44)
150.
(32)
1689 (2
1276 (1
.965
.758
.655
.517
layers.
The magnitude of the
stresses varies with the
res
dep
th
of hardening.
It has been found in harde
ning of shafts, for example, that the
level of the surface compressive residual stres
ses increases with the hardened
depth. In addition, the depth to which the co
mpressive residual stresses penetrate
is usually about
equal to the
de
pth of the hardened
layer.
The combination of a hard surface, compress
ive residual stresses, and a soft
core results in excellent wear and fatigue resi
stance. Improvement in resistance
to bending
fatigue as a
function of ca
se depth in comparison with
furna
ce
treatment
is shown in Fig.
6.15.
Equipment Selection-Frequency
and Pow
er
Density.
The equation
for
referen
ce
depth
(d o ' f ~ f ) can be used to
e
stimate the
optimum power-supply frequency for surface hardening by induction heatin
g methods. Below the Curie
temperature, d (cm) ~
5.8/4f,
or d
(in.) ~ 2 . 3 / ~ , assuming/z =
100. Abo
ve
the Curie temperature (at which #
=
1), d increases by a factor of
10. If he
at
conduction were not important, the sub-Curie re
ference-depth equation would
give
a reasonable
approximation
of
the
austenitized
and
hardened
dept
h.
Because
of heat
conduction,
however,
the case
depth
can
be
substantiall
y
greater,
depending on the time allowed
fo
r conduction. To take this
fac
tor
5 . 8 / ' ~ ) +
o r
Xcase(in.) =
/x/f)
where
tz.
(2.3
+
the
frequency
is
expressed
in
her
Elements of Induc
Design,
Control,
70
483
60
414
e0
n
50
345
~
d
==
'10
"O
40
276
t..
-.
-=
0
30
207 ~
Z
0
Z
20
138
10
69
0.01
0.1
1
10
Milli
ons
of
cycles
to
failure
ponse of furnace
Fig. 6.15.
Bending-fatigue res
hardened and induction
hardened
medium-carbon steel
axles: shaft diameter,
tractor
7.0
cm
.16 cm (0.063
al.,
(2.75
in.); fillet radius, 0
in.) (from T. H. Spencer, et
Induction
Tempering, ASM,
1964)
Hardening
Metals
Park,
and
OH,
Applications
1 15
Table 6.8.
Relationship bet
ween power-supply
frequency and hardeneddepth
obtained using
induction heating
Frequency
al
hardened depth
450 kHz
1.6 mm
m
m
Typic
(0.06
(0.06 to
(0.13 to
in.)
0.13
0.25
10 kHz
...1.6
to
3.2 m
3 kHz
...3.2
to
6.4 m
1 kHz
...6.4
to
9.5 m
in.)
in.)
(0.25 to
(0.37
0.37 in.)
in.) to
180 Hz
full harden-
. . . .
9.5
mm
ability de
pth
60 Hz
enability
. . . .
Full hard
depth
ing and
acid etching.
If the case is to
o shallow, the
power
input
should be
decreased and heating time increased. Conversel
y, if it is too deep, the power
should be increased and the heating time decr
eased. Metallography will also
show the presence of various microstructural con
stituents, such as martensite,
which can be used
as an indication of p
roper
or improper austenitization.
A
second method of determining optimum sur
face hardening parameters
is through the use of nomographs such as those
shown in Fig.
6.16 and 6.17.
Figure 6.16 gives the relationship among gener
ator frequency, applied power
density, heating time, and hardened depth for
steel shafts which are austenitized
at temperatures between
850 and
900
C (1560 and
1650 F) using
a
single-shot induction heating method; this is a
technique in which the entire
area to be hardened is heated at one time
by a coil which remains stationary
relative to the part.
From
the
figure,
it is apparent that,
for a given power
density and heating time,
shallow case dep
ths require higher frequencies, or,
at a fixed
frequency,
shallow
case
de
pths
need
higher
power
densities
for
shorter times. Figure 6.17 is a
designed for surface harden-
similar nomograph
of
Steel
Pipe Welds
Design,
Elements of Induction
Control,
and Applicat
o f brittle
martensite
which
must
be
stress relieved
to enhance
the toughn
ess
and
subsequent
formability.
The
a m
o u n t o f heat generated by welding
a
ffects
the
a m o u n t
o f heat
required
for
subsequent
induction
annealing.
Lowfrequency welding
operations
provide
diffuse heating
and
a wide heat-affec
ted
zone
( H A Z ) , whereas
high-frequency
welding
equipment
produces
a n
arr o w
H A Z .
F r e q u e n c y requirements
for induc
tion
annealing
are typically
f o u
n d by
Table
6.9. Power densities
required for surface
hardening(a)
(from
T.
H.
Spencer, et al.,
Induction
Hardening and Tempering,ASM,
Metals
Park, OH,
1964)
Depth of
hardening(b),
Frequency,
Power density(c), kW/in.Z(d)
kHz
cm (in.)
Low(e)
Optimum(f)
High(g)
500
14
10
0.038
12
(0.015
to
0.1
to
0.045
0.114
8
(0.045
to
0.2
to
0.090
0.152
16
(0.060
to
0.2
to
0.090
)
29
)
29
)
10
10
305
10
0.229
15
(0.090
to
0.
to
0.120
0.305
14
(0.120
to
0.
0.229
17
(0.090
to
0.
to
0.120
0.305
16
(0.120
to
0.4
0.406
14
(0.160
to
0.
to
0.200
0.508
12
(0.200
to
0.71
to
0.280
)
406
10
to
O. 16
0)
305
10
3
15
)
06
14
to
0.160
)
508
10
)
1
1
10
)
914
10
0.711
12
(0.280
to
to
0.
0.350
)
(a) This table is based on use
of proper frequency and normal
over-all operating efficie
ncy of equipment. Values
given
may be used
for static and
progressive methods of heating;
however,
for some applicatio
ns,
higher inputs
can be used
when hardening progressively. (b)
For greater depth of hardening, a lower kilowatt input is
used.
(c) Kilowattage is read as
Design
for
Specific
Applicati
1 17
Har
dened
depth,
in.
0.01
0.08
0.02
0.2
10
200 (129)
100 (64.5)
t-
50 (32.2)
0.04
0.39
0.79
O9
Q)
E
20 (12.9)
E
t m
"O
I
0.5
10 (6.45)
O
O.
o
t~
"E
5 (3.2)
0.2
0.1
G0
2 (1.3)
0.3
2
0.5
5
1
10
20
Har
dened
depth,
mm
Fig. 6.16.
Interrelationship am
ong heating time, surface power density,
and hardened depth for various ind
uction generator frequencies (from
M. G. Lozinskii,Industrial Appli
cations
of Induction Heating, Pergamon
Press, London, 1969)
equating the wall thickness to the reference dept
h of steel above the Curie temperature. With this criterion, the usual fre
quency selections are
10,000 Hz for
wall
thicknesses
up to
0.50
cm
(0.20
in.),
3000
Hz
for thicknes
ses
between
0.32
and
0.95
cm
(0.12
and
0.38
in.),
and
1000
Hz
for
t
hicknesses
over
0.95
cm
(0.38
in.).
Localized
heating through the thickne
ss of the entire HAZ
is provided by
means of a split-return coil and flux concen
trator in the form of a laminated
core. The required power is then a function
of the material flow rate (determined by the pipe speed, HAZ
width,
and wall thickness), the annealing
temperature (which determines the heat content of
the material), and the coupling
efficiency.
The
calculation
is
simplified by
reference to
chart
s
such as that
shown
in Fig.
6.18,
which
giv
es
a
factor
by
which
the
produ
ct
of
the
line
speed,
HAZ
width,
and
wall
thickness
should
be
multiplied
to
obtain
the
power
in kilowatts.
The derivation
of Fig.
6.18
assumes a typical
annealing
temperature
and air gap between
the inductor
and pipe.
----------------------- Page 116---------------------1 18
nduction
Heating:
and Applications
40
(25.8)
.2
Elements
of
Design,
Control,
in.)
A
30
(19.4)
I
2 mm
20
(12.9)
o
Q .
(6!5~
(0
I
(0.15 in.)
3.8 mm
"E
(0.08 in.)
Q)
L9
0
0
2
6
Time
in coil,
(a)
(a) Frequency, 3 kHz; minimum
scanning rate, 6.5 mm/s (0.26
in./s); minimum shaft diameter
, 25 mm (1 in.). (b) Frequency,
10 kHz; minimum scanning rat
e, 50 mm/s (2 in./s); minimum
shaft
diameter,
16 mm
(0.63
in.).
(c) Frequency, 450
kH
z.
o
o: generator, power
, 50 kW; case depth,
1.5 mm (0.059
power,
:
50
in.). o - - - o : generator
kW:
case depth,
1.25 mm
generator power,
1.0
(0.049 in.).
50 kW; case
mm
depth,
(0.039 in.). 0 - - - 0 :
generator power,
50 kW; case depth,
0.75 mm
(0.030 in.).
a - - D :
generator power,
25 kW;
case
depth,
1.5 mm
(0.059
in.). D - n o :
generator power,
25 k
W;
case depth,
1.25 mm (0.
049 in.). - - n :
generator power, 25
among
time
with a coil carrying an alternating current. Various coil and crucible designs
are used for induction melting.
The two most common are referred to as the
coreless furnace (Fig.
6.19) and
the
channel
furnace
(Fig.
6.20).
----------------------- Page 117---------------------Process
Design
for
Specific
Applications
1 19
70
50
~
(19.4)
rdenedcase[depths:
"~
3.8
mm
==
20
~.~.._
(~
(12.9)
(0.15
~
in.)
)
p
~
2.
Io!
'
0
0
3
Time
in coil,
1
4
2
5
(b)
Fig. 6.17.
continued
A
Elements
of
Induction
and
Applicatio
(38
(25
nO
O
O.
}
(12.
0.1
0.6
0.7
0.8
0.2
0.9
0.3
1.0
0.4
1.1
0.5
1.2
Tim
in coil, s
(c)
Fig.6.17.
continued
thus
a small channel in the refractory vess
el which surrounds the coil. This
channel forms a continuous loop with the me
tal in the main part
of the f
urnace body.
By convection, the hot
metal
in the
channel circulates into the
main
nace
body
of the charge in the
envelope to
be
replaced by
fur
colder
ns,
is the lower power input which can be tolerated
for the furnace size. Surface
turbulence within the main metal bath
is considerably smaller, making this
furnace more acceptable when gas pickup and volat
ile metal loss is a problem.
Induction melting units of both types are pri
marily used for refining and remelting of metals
such as aluminum, cop
per, brass,
bronze,
iron and
s
teel,
and zinc. In addition to their use in the ca
sting industry, channel-type induction melting furnaces are also currently being use
d for superheating and refining of blast furnace iron used subsequently in th
e basic oxygen furnace (BOF).
Superheating involves heating of molten pig iro
n to a temperature considerably above its melting point.
By doin
g this, more
scrap steel can be melted
in the BOF using the superheat
the charge from the induction
furnace.
contained
in
Design
Considerations for
Coreless
Ind
uction
Melting
Furnaces
Furnace Design. The main factors to consider
in designing coreless induction
melting
furnaces
are the
crucible/refra
ctory lining,
coil geometry and
flux
guides, and the supporting frame. The refracto
ry lining should be chosen with
----------------------- Page 119---------------------Process
Design
for
Specific Applications
1
21
Pipe thic
kness,
mm
2.5
7.6
5.1
10.2
12.7
60
0.31
0.26
E
E
E
>40
0.20
~
30
0.15
0.1
0.3
0.2
0.4
0.5
Pipe thi
ckness,
in.
*J. Davies
ng Handbook,
n,
1979.
and
50 to
60%
of the
charge has
been
Mol
tenmetal
Spout
l
\
.
~
axis
Refractory....._
Furnace
coil
iiiiiiiiiiiii!iiii
iiiii!iiiiiiiiiiii!iiiiiiiiiiiiiiiiiiiiiiiiiiiiiii
iiiiiii of a
Specific
Applications
12
3
Iron
lamin
tion melting
induc
Size of charge:
Low
frequencies ar
e not
suitable
for
small sizes of
s
crap
because of the low ratio
of particl
e
size to
reference depth until the melt
has progressed sufficiently to
absorb thes
e materials into the molten metal.
If there is a need for constant use of
finely divided materials,
starting wi
th
an
empty furnace is preferable to
using a medium-frequency furnace.
Number
of coil turns:
The
volta
ge induced in the
workpiece
or melt
by
induction heating is proportional to the ac
frequency, the number of turns,
and the strength of the field of magnetic
induction (see Chapter 2). Hence,
to maintain a given voltage, the number o
f coil turns must be increased if
a lower frequency is employed. Thus, a low
frequency requires a large number of turns with small conductors and
small water passages. This leads to
the
increased
risk of clogging and
higher
coil maintenance.
A
high
frequency requires a large number of volts pe
r turn and thus may lead to possible problems with
arcing or electrical
insulation.
Based on the above factors and on years
of experience, it is possible to specify optimal frequencies for coreless induction m
elting as a function of furnace
capacity.
A useful
summary of this
information is given in Fig.
6.21.
----------------------- Page 122---------------------124
ion Heating:
cations
Design,
Elements of
Induct
Control, and Appli
Power Requirements. As
with
inducti
on billet heating prior
to
hot
w
orking,
power selection for coreless induction melting is
largely based on the required
output
in tons
of molten metal per hour
.
For
example, the outputs
of steel
or cast iron that
can be obtained with the
various induction furnaces of one
particular supplier are shown in Fig. 6.22 a
s a function of power rating. For
the most part,
doubling of the output in
a given period of time requires doubling of the power input.
In practice, the power requirement for melting
can be somewhat higher than
that based on the heat capacity of the molten ch
arge and the efficiency of coupling
of the
coil to
the charge.
Fo
r
instance,
about
500 kW. h per
ton
are
needed to melt steel in a furnace with a capa
city of 4 tons or more (Fig. 6.23),
provided that the furnace is emptied once me
lting is complete. However, to
Ib
2.2
2205
10,000
10 kHz
4.2 kHz
3 kHz
looo
1 kHz
22
22,045
220
220,46
L)
r"
O"
180 Hz
150 Hz
u_
100 -
60 Hz
50
Hz
I
I
I
Uncertain
10
10
10,000
1000
100
I00,0
00
Furna
ce capacity, kg
A
= recommended
freque
ncy
regime.
B
= acceptable
frequency.
C
= furnace
freq
uencies
which have
been used
but
which
do not provide good
results. D
= unusable
furnace frequencies.
Fig. 6.21.
Selection of power-s
upply
frequency for coreless induction
melting
furnaces as a function o
f furnace size
(source: Inductotherm)
----------------------- Page 123-------------------
---Process
Design for
Specific
Applications
125
10,000
Normal
~'
~22,050
maximum/
" ' ~ Y
II
'
""~ ~
15,435
Assuming
power
/-
~
pouring
t
n
/.~
at 1650C
~ "
(3000 oF)
"
11,025
~
~
4000
3000
2000kw /
/
'''- ~
""~ f
,w,,~ ~
6615
I
I
2000
-,'~
f " ~
-
4410
1500
1000kWjl/"
/ /
/ ~
/ I
1000
80
/
kW ~
~7
!205
I
. , f /
I
700
~
600 kWj , , ~ , p , - . -
. f
..=,_
~
f
7 "
1544
f
500
/
1103 _____
>~
Q.
O~
40o
~
o
0
0
I
300
~
E
U_
200
7
662
o.
i
i /
350 kW
# ;'7.
/
~
~
441
I
/
~/
~
"
3ookw,
~
A
/
1O0kW
] /
100
20
I
kW
V /
I
220
A /
/
70
/Air
/
154
/
Normal
i
maximum
50
"
110
J
time
40
88
!
Approximate
30
multiplier for
66
,//
cast iron to
1500 C (2730 OF),0.78
2O /
44
10
22
70
70
80
180
0
90
10
20
100 110
30
40
50
60
120 130 140 150 160 1
Elements
of Induc
Design,
Control,
and A
I
650
ro
I
I o
600
Furnace manufacturer
tapping
A:
temperature
1450 C
40 F)
(26
t -
550
O
Q,.
O
O
~'O~
Furnace manufacturer
tapping
C:
~ .
O
1500 C (273
temperature
0 F)
0
o
8
0
O_
500
m
Furnace manufacturer
tapping
B:
temperature
1450 C
(26
40 oF)
450
-I
I
I
5
15
20
Furnace capacity,
quoted
by
I
10
25
30
Fig. 6.23.
furnace
Power
consumption
manufacturers
f
or
ine-frequency
ous
ns and J.
c
melting
induction
of cast iron
in
l
furnaces
of
vari
capacities
Powell, Prnc.
(from W. A. Parso
Conf.
on Electri
on Foundries, University
March,
of Warwick,
1980,
p 18-1).
the
ratio
of
power
to furnace
ca
pacity
must
be
kept
low
when
this
kind
of
equipment is used.
For
example,
if an output of 2.5 tons of molten
steel per
hour is obtained from a 6-ton-capacity furna
ce supplied with
1500 kW
of linefrequency power,
then the same outpu
t can be obtained from a 3-ton,
150-Hz
----------------------- Page 125---------------------Process Designfor SpecificApplications
127
Table 6.10.
Normal maximumfurnac
e power ratings
(from "Medium FrequencyCoreless F
urnacesfor
Iron
700
1000 to
1400
Po
ope
200
Hz
1. . . . . . . . . . . .
600 to 800
2 . . . . . . . . . . . .
1200 to
1600
1500 to
2000 to
2100
3 . . . . . . .
1800 to 2400
4 . . . . . . .
...
5 . . . . . . .
...
6 . . . . . . .
...
2800
2500 to
3500
3000 to
4200
. . 1500 to 1800
. . 2000 to
2400
. . 2500 to 3000
. . 3000 to 3600
furnace
of equivalent
power
rating.
Typical
power
ratings
for coreless
urnaces
of several different
frequencies
are
given
in Table
6.10.
channel
constrain
Channel Induction
induction
metal
to
n a
narrow
with
channel,
problems
bath
turbulence
are
tered.
Hence,
such
furnaces
melting
flow
i
associated
not
encounare
almost
use,
which
typically
of four
categories:
falls
into
one
Continuous
charging
from
elsewhe
re (duplexing).
In this case, the
furn
ace
is used
to homogenize
the compositi
on
and
temperature
of the melt.
A
capacity
of about
one
hour's
supply
is usually
sufficient.
*"Molten heel" refers to the molten pool left i
n the furnace after tapping.
tW. A.
Parsons
and J. Powell, "Design an
d
Operational
Factors
Affecting Energy Consumptions,"
ces in Iron
ference Held
1980, p
128
ng:
Design,
Process
Design for
Specific
Applications
129
edges is not deleterious. On the other hand,
the edges of aluminum, copper,
and
brass
strip
should
be
fr
ee
of
oxides
because
very
la
rge
voltages
are
required to break down the contact resistance
in these situations. When this
barrier
is suddenly broken,
in
consistent welding results are obtained.
Faming. The forming of strip prior to induction
welding is somewhat different
from the processing which precedes electric-res
istance welding. In the latter
"
6001
I
I
I
I
I
I
I
O
500
400
0
0
O
CL
q
O I
I
I
t O J
300
10
-6
cQ)
O
eLL
200
0
Semidrum or
bat
h
100 I
O
Horizontal drum
Z~
Vertical drum
ol
13
Pouring furnace
I
I
I
0
40
80
Furnace capacity, t
20
60
power
channel
Fig. 6.24.
Total
requirements
for
holding
industrial
induction furnaces
of various c
apacities (from W. A. Parsons and J.
PoweU, Proc.
Conf.
on E
lectric Melting
and Holding
Furnaces
in Iron
Foundries,
University
of
Warwick,
March,
1980,
p
18-1; an
d British
Fuundryman,
Vol 76,
No.
10, October, 1981,
p 212)
----------------------- Page 128---------------------130
ng:
Design,
A
seam guide is
immediately after
thin blade
the
Design
for
Specific
Application
131
/-
,%
C
I
I
I
(a)
(b)
(c)
Fig. 6.25.
Squeeze-roll arrange
ments for induction
tube welding: (a) tworoll; (b) two-roll with
supple
mentary roll; (c) three-roll (from J. Davies
and P. Simpson,
g Handbook, McGraw-Hill, Ltd.,
don,
1979)
Induction Heatin
Lon-
Welded
seam
'
Induction
coil
~ J ~ , L . . -
~
\ ~ . _
\
I1~ , , ~ "
~ ~ ~ ~
Eddy-currentpath
th
in
~ ' ~ ' ~
Fig. 6.26.
high-frequency
Eddy-current
pa
induction
welding
of
tubular
products
(from
C.
A.
Tudbury,
Basics of Induction Heating,
Vol
1, John
F. Rider,
Inc.,
New York,
1960)
----------------------- Page 130---------------------132
Heating:
Design,
ID and tube or
57
25
Elements
of Induction
Control, and Applications
19
45
13
38
6
32
0
20
508
18
16
\
406
14
\
356
12
305
E
E
5
5
O
\
O
O.
t~
10
254
o.
"
F,
.Q
I-
8
\
203
.\
152
\
102
51
\o
1.0
l
2.25
0.75
ID and tube or
2.0
1.75
0.50
1.50
0.25
1.25
0
but
of
the
because
the
short
tube
of the
path,
is small,
again
l
t
le
Design
Features
frequency
facto
Frequency Selection.
As
in pipe
seam
annealing,
frequency requirements are
found by
equating the wall thickness to
the reference depth d.
In a
ll cases,
#
= 1 in the equation for d, because stee
l is welded well above the Curie temperature.
For typical wall thicknesses (i
.e.,
up to
0.38 cm,
or 0.15 i
n.),
the
Table
ship between
6.11.
Relation
outer
Impeder
Nominal
length, cm (in.)
tube
size, c
1.3 (0.5)
. . . . .
. . . . . . . . . . . 25.4 (10)
2.5 (1) . . . . . .
. . . . . . . . . . . . 25.4 (10)
3.2 (1.25)
. . . .
. . . . . . . . . . . 25.4 (10)
3.8 (1.5)
. . . . .
. . . . . . . . . . . 30.5 (12)
5.1 (2) . . . . . .
. . . . . . . . . . . . 38.1 (15)
6.4 (2.5)
. . . . . . . . . . . . 38.1 (15)
11.4 (4.5)
. . . . . . . . . . . . 38.1 (15)
. . . .
. . . .
Elements of
Design, Control, and
Indu
Wa
ll thickness, in.
0.04
0.2
0.24
0.08
0.28
0.31
I~
I
1.0 ,~
0.12
0.16
0.35
0.
39
I
I
'
I
'
]
X
.o
l
2.5
5
~
~
t
p
~
98.4
_
\ \ \ \ \
X
I
/
\ \ \ \ X \
\
o
{=2.0
" ~
X
/
1.5
59.1
~-
~
Diameter,mm
1.0
39.4
O.
200kW
250kW
/
i
kW 150kW180kW
0017911
I
I
I
/ o
0
I
1
I
I
4
9
10
Wal
l thickness, mm
For other outer diameters, th
e welding speed should be multiplied by the correction factor
given in the inset. For other metals, the
speed should
be multiplied
by
1.4 (aluminum),
1.1
.9
(stainless
Fig. 6.28.
function
of wall
as a
put
power
(1-in.-) diam
-ramcP.
(brass),
steel).
Simpson,
0.8
(copper),
Welding
thickness
speed
and
or
in
for fabrication
of 25
steel tubing
(from Indu
1979)
required
generator
frequency is in the
radio-fre
Specific
Applications
135
Table 6.12. Chemical compositionsand
melting ranges of
alloys commonly used in induction sold
ering (from J. Libsch
and P. Capolongo,lepel Review,Vol 1 ,
No. 5, p 1)
Alloy
I
Composition,
Melting range, C (F)
I
er
No.
Liquidus
Tin
Solidus
Lead
1
(450)
2
(361)
3
(370)
4
(420)
5
(460)
6
(500)
7
(590)
8
(603)
99.8
230 (450)
62
185 (361)
60
185 (361)
50
185 (361)
40
185 (361)
30
185 (361)
...
310 (590)
...
310 (590)
...
230
185
190
215
240
260
310
315
wt %
Silv
38
40
50
60
70
97.5
2.5
96.5
3.5
and
of
an
6.13)
are
selected
on
the
bases
of
Design,
Elements of
Control, and Appl
1
~__o
o o
....
. m
v
, I I
0
I I
I I
, M
<
E
E
E
0
U
m
~
" Z z
<
~
U
~
+
+
"
~
0
E'|
"|}
~
'
Design
for
Specific
Applicatio
137
melting-temperature range, ability to wet the
metallic surfaces to be joined,
and the tendency to oxidize and/or volatilize. A
dditional selection criteria frequently include the strength and ductility of th
e alloy and unfavorable metallurgical reaction with the metals to be joine
d.
As in soldering, clea
ning and
fluxing of the
surfaces to be joined
mm
0
0.15
0.36
0.05
0.2
13.5
135
0.1
0.25
0.3
(93.1)
I
(930)
Strength of joints
12.0
in relation to
120
(82.7)
clearance
(827)
~"
between
surfaces
O .
10.5
I
105
. . . . . .
v
I
(72.4)
(724)
.
9.0
90
(62.1)
\
~
(621)
c
Silver alloy
7.5
75
(51.7)
(517)
C
e-60
(414)
~"
" 0
4.5
45
0
if)
(31.0)
310)
>
3.0
30
(20.7)
--
207)
1.5
15
(10.3) 0
0.006
0.014
0.008
0.002
0.010
0.004
0.012
103)
Thi
ckness of joint,
nt
of
in.
Fig. 6.29.
Influence
of joi
on theoretical
strength
thickness
sol-
from
F. W.
dered
Curtis,
and
brazed joints
(
High Frequency Induction
Heating, McGraw-Hill,
York,
1950)
New
Design,
Elements
Control,
of
and
Induction
Applicati
ons
O = Length of overlap = 3T
T
= Thickness of thinner
member
~
I
!'
T
Lap
joint
But
t joint
/
Scar
f joint
Normal cross-sectional
Joint area = 3A
area = A
Fig. 6.30.
Basic brazing joints: l
ap, butt, and scarf (from J. Davies and
P.
Simpson, Induction Heating Han
dbook, McGraw-Hill,
Ltd., London,
1979)
L,
C
Modified butt joint
Butt joint
Modified lap joint
s
But
t-lap joints
Fig. 6.31. Modified brazing joints
(from J. Davies and P. Simpson, Induction Heating Handbook, McGraw-Hill,
Ltd., London, 1979)
----------------------- Page 137---------------------Process
Design
A p p l i c a t i o n s
for
Specific
1
39
~c
0
a~
u~
[
--o.~
I~I
~1
~.-_
. 2
"
~ ,
~
o
~o-~
~ . -
~'
'~
o
~
_ e o 0
-
i~
~.~-
-==
E ~
,.," ,m0
0
0
O
ill,.
(.9
t
i !
~
d
N
i '
~Ec~
E
"
0
0
0
Eo~
~--
O0
-~(..9
~
o
I
I ' ~
- I
~E~
c
o.~
8
"o
"6
~.~
.~
if)
~
E
O ~
r"
U)
->'--
~0
~
O
D . ~
o~
~
~ _ ~ - - ~
I
"
c
o . , ~
c . _
~
.,
- - ~ -
-8
.F: .o
~
o
140
Induction
Heating:
Elements
Design, Contr
ol,
and
Applications
10
6.5
9
5.8
8
~ / /
5.2
7
4.5
\
6
"
3 . 9
~V
o p p e r
5
3.2
O9
e"
"0
\
02
" 0
0
2 . 6
O.
rl
rassandbronze\
\
3
1.9
2
"
1 3
-- sS~aeiel(ms~gn e t i c ~
~
10
30
70
40
50
20
60
80
Heatingtime,s
Fig. 6.33.
Recommende
dpower-density ranges (between broken lines)
as
a
function
of
heating time
for
radio-frequency soft
soldering at
188
C (370
F)
(from J.
Davies and P. Simpson, InductionHeat
ing
Handbook, McGraw-Hill,
Ltd., London, 1979)
Power densities for induction sold
ering and brazing are similar to
or slightly
lower than
those
for
surface heat
tr
eating
of
16.1
2O
12.9
Applications
+_
#'/
~ p p e r
9.7
~P
0
CL
nO
lO
/
6.5
s
~ a s
//
and bronze
/
3.2
Stee,<maget' anD
L
stainless)
o
0
0
40
10
50
90
20
60
30
70
80
Heating time, s
ensity
Fig. 6.34.
Recommended power-d
ranges (between broken lines)
of
Process
a
large extent on judicious control of
input power, heating time, and part handling. Because induction systems are
based on an electrotechnology, the coupling of the heating equipment to t
he electric-based control system is readily
facilitated.
The
ease
of control
in these
situations
can
be contrasted
to
nonelectric-based ones, such as fossi
l-fuel heating, in which problems such as
those associated with thermal inertia o
f the furnace make quick response, process control,
and high-speed automa
tion more difficult.
The important elements of almost
all process-control systems for induction
heating include the following:
A device or method for measurin
g workpiece temperature. This often consists of an instrument to be giv
en a direct indication of surface or subsurface temperature (e.g., a thermocoup
le or radiation pyrometer). It can also
consist of some indirect measuremen
t that can be correlated to the temperature or heating pattern in the
induction heated workpiece, such as measurement of coil impedance or o
f coil voltage and current.
A controller for comparing the
temperature of the workpiece to
a
preset
desired temperature.
A power-control device for regula
ting the power of the induction generator, or a device for controlling
the heating time.
143
----------------------- Page 141---------------------144
eating:
Design,
Elements of Induction
Control, and Applications
Methods
of monitoring temperatures
during induction heating have been
reviewed extensively in the technical literature.*
The most common techniques
make use of thermocouples and radiation detec
tors. Despite the widespread
use of each method,
several major problems
should be considered before a
final selection is made.
These include pro
blems
of poor
workpiece surface
condition, contact resistance, and response time
for thermocouples. With radiation devices, emissivity variations
are
the major
case of concern.
Thermocouples
Although thermocouples are not
suit
able for all applications, they provide
good accuracy, measurement capability over a ve
ry broad temperature range,
ruggedness, reliability, and low cost. Thermoel
ectric thermometry is a mature
technology whose principles
have
been
known
since the
early
1800's. It is
based on the well-known relationship between
a difference in junction
temperatures and the resulting voltage (emf). In
practice, the reference junction
is held at a constant
known
value by v
arious
means-e.g.,
an
ice bath, a
controlled-temperature furnace, or an electrical
method of simulating a known
temperature.
The temperature of the heated ju
nction
is determined by measuring the voltage and referring to calibrat
ion tables for the particular thermocouple
materials.
Thermocouples
are of two
basic
types:
contact
and
noncontact
(or proximity).
Contact Thetmoconples. There
are
us
types
of contact
thermocouple
vario
of
Process
Control
145
involves the direct attachment of a thermocoup
le to the part whose temperature must be determined. Typically this is don
e by percussion welding of the
individual thermocouple elements to the part sur
face approximately
1 to 2 mm
(0.04 to 0.08 in.) apart.
This procedure
is impractical for measuring workpiece temperatures in most induction heating p
rocesses because of the presence of an induction coil (single-shot and sc
anning applications) or the fact
that the part is moving through the coil (scan
ning methods of induction heating). For this reason, contact thermocouples
are normally used during initial
trials to set up a particular process.
ther
H
older
Fig. 7.1. "Open-prod" proximity ther
mocouplefor makingtemperature
measurements (from N. V. Ross,Proc.
Sixth Biennial IEEE Conference
on Electric Heating, IEEE, New Yor
k, 1963,
p 29)
----------------------- Page 143---------------------146
ing:
Design,
on
both the part and the thermocouple itself
. The open-prod thermocouple
is not capable of measuring temperatures of met
als harder than the thermocouple
elements
themselves.
These
harder
metals
include
steels, titanium
alloys, and nickel alloys. In these instances
, noncontact thermocouples are
appropriate.
Noncontact (Proximity) Thermocouples. To
ove
rcome the difficulties associated
with scale formation, proximity thermocouples a
re often utilized. In this type
of device, the thermocouple junction is attached
to a disk of stainless steel or
other high-temperature alloy. The disk (with th
e thermocouple attached to it)
is welded on the inside and near the end o
f a stainless steel tube which acts
as the temperature probe.
By this means, th
e temperature-measuring device
is isolated from the dirt and scale associate
d with the heating process. The distance between the disk and the workpiece sur
Type "S":
Pt vs. Pt-10Rh.
Used up to
1650 C (3000
F).
Type
"T": Cu vs. Cu-Ni
(constantan).
Used up
to 400 C (750
F).
There are also some very-high-temperature th
ermocouples based
on tungsten. For example, tungsten-rhenium thermocoupl
es find use at temperatures
up to approximately 2200
C (4000
F).
Special Considerationsfor Therm0couples. Because
temperature
measurements
made with thermocouples rely on the developm
ent of a dc voltage,
due con----------------------- Page 144---------------------Fundamentals
of
Process
Control
147
Errors
due to the disparity
in thermal
emf
between
thermocouples
and
nominally identical extension-wire components
of types EX,
JX,
KX,
and
TX.
Errors due to temperature differences betw
een the thermocouple/extension
wire junctions.
Errors
of this sort are
most troublesome for extension wire
types WX
and
SX.
Errors
due to reversed polarity at ther
mocouple/extension wire junctions
or at extension wire/measuring
instrume
nt junctions.
Although
a single
reversal of polarity
in the assembly would
be
noticeable,
an inadvertent
double reversal
may
likewise produce
m
easurement
errors that might be
more
difficult to detect.
Further discussion of problems
th extension wires is given in
associated
wi
ASTM
Special
Technical
Publication
470.*
Elements
of
Design,
Control,
.~,~
Ind
an
I ~cS
.9,~
.~
+1
+1
+1 +1
+1
+1
+1
+1
+1
+1 +1
+1
+1
+1 +1
~ a
2 2 2 2 2 2 2
~F
2 2 2 E 2 ~
I
o
O
E~
i
~ r ~
~ 0
0
0
O
o
O
"O
O
Z
o
L
~
.a
+.,
O
"O
o
----------------------- Page 146---------------------Fundamentals of
Process Control
149
he
Detectors
common types of
and infrared
radiation
devi
y considered
for process
accurate
control.
enough
Infrared
Pyrometers. Infrared pyrometers are
rapidly replacing optical pyrometers for many applications. They are more
accurate (0.5 to
1%0 of full scale
as opposed to
_+2% of full scale for optical p
yrometers), and they can be used
as portable
sensors or as part of a permanen
t, continuous temperature monitoring and control system. In addition, the
readout can be analog
or digital.
Although there
are many variations,
the i
nfrared pyrometer basically operates by comparing the radiation
emitted b
y the hot target with that emitted
by an internally controlled reference source. T
he output is proportional to the
difference in radiation
between the variable
source and the
fixed reference.
There
are three types of infrared pyromet
ers:
Single-color or single-band pyrometers, whic
h measure infrared radiation
of a fixed wavelength. These are the most v
ersatile pyrometers because they
are suited to many applications. Their accur
acy may be affected by the presence of dust, atmospheric gases,
and ot
her characteristics
of the
measuring environment, and the emissivity of the
target object must be taken into
account.
Single-color pyrometers operating
at shorter wavelengths tend to
be more
accurate
at high temperatures.
Broad-band pyrometers, which measure the
total infrared radiation emitted by the target. The accuracy of this t
ype of pyrometer is also adversely
affected by the presence of dust, gases,
and
vapor.
Similarly, errors in measurement can occur unless the emissivity of th
e target is taken into account.
Two-band or two-color pyrometers, which
measure the radiation
emitted
at two fixed and closely spaced wavelengths.
The ratio of the two measurements
is used to determine the
tempera
ture
of the target. The
adverse
effects of the environment (dirt, gases,
and vapors)
are largely eliminated
with this pyrometer.
Moreover,
because
emissivity affects both
measurements equally,
its effect on accuracy is
eliminated.
Of the three types, the two-color pyromet
er is surely the most accurate. As
are the other types of pyrometers, it is readil
y adaptable for measuring of temperatures in induction heating systems using a
variety of optical systems for
focusing and,
as mentioned above,
using
fiber optics.
----------------------- Page 148---------------------Fundamentals
of
Process
Control
151
140
120
100
or)
t -
80
60
r r
..
40
k
. ~
4000
3000
K (7200
R)
K (5400 OR)
0oo
0ooo.,
/
20
0
0
2
1
3
4
Wavelength, pm
(a)
Fig. 7.2.
Spectral-radiancy cu
rves for (a) a black body at three
different
temperatures and (b) t
ungsten and a
black body at
2
000
K
(3600 R) (from D. Halliday and
R. Resnick,Physics,Wiley, New York,
1967)
Theory
of
Operation of Infrared
Pyr
ometers.
As mentioned above, infrared pyr
ometers measure the radiation given off by th
e heated object. An
internal calibration
is used
to
convert
the
radiation
level to
temperature.
The
manner in
erstood by
precise
which this is done can best be
reference to
spectralcurves
such as those
Fig.
7.2.
These curves
und
radiancy
given in
rep
resent the
spectral radiancy,
R, or the amou
nt of energy emitted by the body per unit
time
for
wavelengths covering the
interval
from
)~ to
X +
dX.
Single-color
pyrometers measure the total radiation power,
Rd~, over the nar
row wavelength band to which their pickup device is sen
sitive. Infrared pyrometers are
designed for wavelengths in excess
of those to which the naked eye is
sensitive (0.4 to 0.7 #m, or 0.016 to 0.028 mil).
Typical wavelengths employed usually lie in the range between 0.7 and
20/~m
(0.028
and
0.79
mil).
----------------------- Page 149---------------------152
n Heating:
ions
Design,
Elements
Control,
50
40
E
30
Cavity radiator
0 K (e = 1.0)
of
and
Inductio
Applicat
0
I I
20
~
Tungst
en
at 2000 K (e
-- 0.26)
\
10
~ . . . .
0
3.0
.0
1.0
4.0
2
5.0
Wa
velength, pm
(b)
Fig. 7.
2. continued
Upon examining the curves in Fig. 7.2(a) for
a material with an emissivity e
equal
to
1.0 (a
so-called black
body),
it is apparent
that,
for a given
w
avelength X, the value of Rx is very sensitive
to temperature.
Therefore,
Rx
,
or
the voltage it induces in the
detector
in the pyrometer,
is readily calibrat
ed
against temperature.
For real materials
,
however, the emissivity is not
unity
(except
for heavily
scaled or
oxidized
surfaces);
rather,
it assumes
a
value
between 0 and
1 (Table 7.2). Nonetheless
, the relationship between the spectral radiancy of a real material
and
the idealized black body
is quite sim
ple:
Rx(e
:~ 1)/R(e
=
1) =
e. This
r
elationship*
is usually
assumed
to
hold
irrespective of X for a given workpiece temp
erature
(Fig.
7.2b)
and
is
relied
upon
in the operation
of single-color p
yrometers.
These instruments have an
emissivity adjustment which permits the voltage
generated to
be multiplied by
a factor
of 1/e prior
to its comparison
with that
which would
be produc
ed
by
a black
body.
*In actuality, the emissivity e is defined as t
he ratio of the total radiancy of a heated object
(f RxdX, integrated over the entire wavelength ra
nge) to the total
radiancy of a black body
heated to the same temperature.
However, the
ratio of the Rx's at specific wavelengths is
often taken as being equal to a constant (= e) ir
respective of X; this is a reasonable assumption for most engineering applications.
----------------------- Page 150---------------------Fundamentals
of
Process
Control
153
Table
7.2.
s
source:
Typical
Ircon,
emissivities
Inc.)
of
metal
I
I
Emissivity
[ - Emissi
vity
I
Smooth,
th,
Smooth,
Material
zed
Material
oxidized
Alumel
.90
Smoo
Smooth,
polished
oxidi
polished
. . . . . . . . . . . 0.25
0
Nichrome . . . . . . . . . .
0.26
0.90
Aluminum . . . . . . . .
0. l0
0
.20
Nickel . . . . . . . . . . . . . 0.15
0.90
Brass . . . . . . . . . . . . . 0.10
0
.70
Platinum
. . . . . . . . . . 0 . 1 8
. . .
Carbon steel
. . . . . . 0.25
0
.75
Silicon
. . . . . . . . . . . . 0.70
...
Chromel . . . . . . . . . .
0.25
0
.90
Silver
. . . . . . . . . . . . . 0.03
0.80
Chromium . . . . . . . .
0.30
0
.70
Stainless steel
. . . . . . 0.25
0.85
Cobalt
. . . . . . . . . . . 0.25
0
.75
Tantalum . . . . . . . . . . 0 . 1 0
0 . 7 0
Copper . . . . . . . . . . . 0.04
0
.70
Tin
. . . . . . . . . . . . . . . 0.22
0.60
Graphite . . . . . . . . . . 0.65
..
.
Tungsten
. . . . . . . . . . 0.10
0.60
Iron
. . . . . . . . . . . . . 0.25
0
.70
Vanadium
. . . . . . . . . 0.29
0.75
Lead . . . . . . . . . . . . . 0.15
0
.70
Zinc
. . . . . . . . . . . . . . 0.07
0.50
Manganese . . . . . . . .
0.30
0
.90
Zirconium . . . . . . . . .
0.22
0.40
Molybdenum . . . . . .
0.28
...
The temperature error due to an incorrect
emissivity setting of a single-color
pyrometer is readily calculated from the
formula*:
AT(%)
=
Ae(%) [ h-~2]
In this
equation,
AT
and
Ae denote
the temperature
and
emissivity
errors,
respectively,
and
h, T,
and
C2 re
present
the
pyrometer
wavelength,
workpiece temperature,
and Planck's secon
d radiation constant (0.0144 mK).
As
an
example,
consider
the
case
i
n which
the
temperature
of
a
st
eel bar
at
1000 C (1273 K) is being measured with a
single-color pyrometer
sensitive
to radiation at
1 gm. Assume that e
=
0.60, but that the emissivity setting
on
the pyrometer
is 0.90.
Thus,
Ae
=
500/o, and
AT
=
(50)(1
X
10-6)
(1273)/
(0.0144) =
4.427o =
56 K
=
56
C. The pyrometer would thus indicate a value
which is low by
56 C.
It is obvi
ous that
low settings of emissivity produ
ce
Design,
Elements of Ind
Control, and Applicati
100.0
80.0
1200 C
(2190
F)
0
l ,
o
60.0
o
z_
900
o C
2
(1650
F)
2
q)
(1)
Q.
E
40.0
E
I-I-600
o C
(1
110
F)
20.0
300
--
C
' / j J
(570 o F)
0.0
0.0
2.0
1.0
3.0
4.0
5.0
6.0
Wav
elength
of
pyrometer, pm
Fig. 7.3.
r as a function
r wavein emissivity
B. Wareing,
Temperature
erro
of infrared
pyromete
length for
adjustment
10% error
(from J.
R.
Vanzetti, Industrial He
5
6.
of
Process
Control
155
following:
tuations.
Other techniques are
currently under
development and
may
find
some use
in the future.
These
methods include those based on ultrasonics, ed
dy-current detection, and realtime
measurement
of coil current
or i
mpedance
during
induction heating.
Each
of these is briefly discussed below.
UltrasonicMethods.*
Ultrasonic temperaturemeasuring techniques make use
of transducers which generate and detect sound
waves in the workpiece. The
velocity of sound for a given material is
a function of the material's
elastic
modulus and density. Because these properties ar
e functions of temperature,
the speed of sound can be used to infer temper
ature. Transducers under evaluation
to determine
their ability to ge
nerate
the
required
acoustic
waves
include varieties
such as electromagneticacoustic,
electromechanical,
and
high-intensity lasers. These n o n c o n t a c
t transducers are all designed to overcome
one
of the
prime
difficulties
ass
ociated
with
ultrasonic
temperature
measurement-the
difficulty of getting
the
sound waves into
and
out
of a
heated workpiece. Mechanical-contact methods usi
ng cooled buffer rods have
been used,
but do
not lend themselves re
adily to production
applications.
A
second problem
associated
with
u
ltrasonic
temperature
measurement
relates to temperature distributions in bodies
with temperature gradients.
If
ultrasonic velocity measurements are used to
infer temperature,
the soundwave velocity is usually some average along the p
ath of propagation.
To find
Watson,
Part 1,
Advances
in Instrumentation,
1982, p 267.
of Process
Control
157
wave-propagation times for an appropriate set
of ultrasonic rays.
Ini
tial resuits obtained using noncontact laser-generated
ultrasonic waves have been
encouraging, although only a relatively coarse pi
xel size has been used to date.
A related CAT technique for estimating temp
erature profiles makes use of
the
change in resonant
frequency as
a
function of temperature.
By m
aking
several resonance measurements at a single poi
nt on a slab or billet, a graphic
profile
of internal temperature can be plot
ted.
lope ~
0.6
m/s. C
~S
Trans
ducer
0
o
La
ser
>
pulse
/kx
-..,.~
0>
304
Temperature
SS
(a)
(b)
ngth
L
~
eceivers
Source
ds
Transit
time
=/
"
m
L
V(r)
m
(c)
Fig. 7.4. Tomographic
recons
truction of the ultrasonic velocity-temperature distribution in a solid
bar: (a) schematic velocity-temperature
curve for a uniformly heated
bar, (b) schematic illustration of equipment setup,
and (c) diagram
i
llustrating method of data analysis
(from
R. Mehrabian and
H.
N. G. Wa
dley, Journal of Metals, Vol
37, No. 2,
February,
1985,
p 51)
----------------------- Page 155---------------------158
ting:
Design,
an
F)
could
of
540
Coil-Current Monitoring.
A relatively new tech
nique for
obtaining an
estimate
of the temperature
profile
within an
ind
uction
heated
workpiece
involves
direct monitoring of the current through the
work coil. It is similar to eddycurrent techniques in that it relies on changes o
f impedance with temperature.
One of the most interesting of such applicat
ions deals with case hardening of
*D. E. Stutz,unpublishedresearch,Battelle'sColu
mbusLaboratories, Columbus, OH, 1986.
----------------------- Page 156---------------------Fundamentals
of
Process
Control
1
59
steels
cribed
by
a
by
single-shot
Verhoeven,
method
Downing,
as
des
and
Gibson.*
In case hardening, a surface layer is raised
to austenitizing temperature,
fol
lowed by
quenching.
Workpiece
resi
stance,
and
therefore
coil impedance,
varies
as a result of changes in resistivi
ty with temperature
as
well
as wi
th
phase changes. As discussed by Verhoeven and
his colleagues, three distinct
stages can be identified in the process of
surface austenitizing by induction:
1.
stage: All
iron.
current
flows
flows
both
iron.
in
paramag
gree
of end effects.
Verhoeven et
al. also demonstrated
the Ic vs. t behavior
can be
tha
cor
t
related to the austenitized-and-hardened case d
epth, denoted by ~case. This is
done by examining the
energy input int
o the workpiece:
Energy input per
area
unit
PA dt
m
~ dt
and
case depth ~case was
in the
experiments carried
authors,
7.
ut
by
6.
these
as
shown
in
Fig.
160
Induction
l,
and
Heating:
Applications
-
Elements
Design,
of
Contro
2OO
15o
,,_z
(,,g
--
100
P
I
--
50
~
5
t
t
p
m
Time
Fig. 7.5.
rent-versus-time
Schematic coil-cur
curve for a stee
bar
sur-
face
hardened
by an
induction
heating
method.
The
times
tm and tp
separate the three stages f,
f/p,
and p (from J. D. Verhoeven,
H. L. Downing, and E. D. Gibson, Journal
of Heat Treating,Vol 4, No. 3, June,
1986,
p 253)
Load-SignatureAnalysis.
A techniqu
e similar to coil-current monitoring, but useful for a variety of induction heating proc
esses
(including he
at treating),
is
the one known as load-signature analysis. In
this method, a number of characteristics of the induction heating circuit ar
e monitored and compared with
values
known
to
give the
pr
oper
heating
cycle. These
parameters
usually
include*:
*G. Mordwinkin,
A. L. Vaughn,
and P.
Hassell, Heat
Treating,
V
ol
18, No.
11, November,
1986, p
34; P. A. Hassell and G. Mor
dwinkin, Industrial Heating, Vol 53, No.
12, December,
1986,
p
17.
----------------------- Page 158---------------------Fundamentals
161
of
Process
Control
Current
and voltage versus time
Phase angle (between current and voltage)
versus time
Frequency of the
applied voltage.
Figure 7.7 indicates how current (CT) and
potential (PT) transformers are
connected in either a constant-current (i.e.,
solid-state) or constant-voltag
e
(i.e., motor-generator) heating circuit to get
the data required to
do
cument
the induction heating
"signature."
Mordwinkin, Hassell, and their coworkers ve
rified the usefulness of loadsignature analysis through
a number
of experiments involving pipe heating
and
camshaft hardening.
The
form
er trials
indicated that
incorrect h
eating
arising from gross geometric variations of the
workpiece was readily discerned
by signature analysis; however, none of the si
gnature parameters listed above
gave an unambiguous indication of heating diff
erences associated with pipe
warpage or the presence of through holes in
the pipe wall. In the heat treating runs, load signatures were found to be dist
inctly different for sound versus
cracked cams. Axial cam offsets in the coil o
f approximately 257o were also
readily detected by this method.
O
n the other hand,
radial mispositioning
of
the workpiece showed little effect on the signat
ure, particularly at low powersupply
frequencies for which centering is o
ften not
critical anyway.
Sl
...]127
4 I--/ "
.--!102
E
E
-
3
76
.c"
1
nO
"0
0
G
2
51
<C
<
25
of
I
I
1
2
parameter, A2s x
3
Energy-input
10-s
Fig. 7.6.
by
induction surface
hardening of a steel
bar as a
function of ~'lZdt,
where I, and
t denote induction
coil
cur
rent and time,
respectively
(from J. D. Verhoeven,
H. L. Downing,
and
E. D. Gibson, Journal of Heat
No. 3, June,
1986, p 253)
eating, Vol 4,
Tr
Design,
Elements of Induction H
Control, and Applications
"Start"
Ca
pacitance
t
bank
Amplitude
CT1
frequency
phase
^ ^
_ / v L
II
R1
l
Ill
Load
Induction
coil
Inverter
(constant
current)
, - ~ , P h a s e
- I ~
(
a)
"Start"
Ca )acitance
t
Phase
I
t'' l
Inductor
I
Load
I
Matching
MG set
transformer
(constant
Am
plitude
voltage)
u e n c y
~ ' ~ D ~ f r e q
phase
(b)
Fig. 7.7. Use of current (CT) and
potential (PT) transformers to obtain
induction
heating "signatures"
for systems
utilizing (a) a constantcurrent (solid-state) power
suppl
y
and (b) a
constant-voltage
(motorgenerator)
power
supply
(from
G. Mordwinkin,
A. L. Vaughn,
and
P.
Hassell, Heat Treating, Vol 18
, No. 11, November,
1986,
p 34)
Other applications of load-signature analysi
s as discussed by Hassell et aL
include determination of the influence of adjace
nt metal structures on heat-
ing patterns
and troubleshooting of tankor
output-circuit components that
might affect system performance. The latter in
clude faulty tank-circuit capacitors, high-resistance or loose bus connection
s, and changes in high-current,
low-voltage bus
spacing.
Malfunctions
of induction generator
controls
for
constant
output
of voltage,
current,
or power
are also
revealed
by
l
oadsignature analysis, as are coil overheating (
due to inadequate cooling-water
flow
or poor
contact
in clamp-type
inductors)
and
deterioration
of
f
luxmodifier materials.
----------------------- Page 160---------------------Fundamentals of Process Control
163
TEMPERATURE-CONTROL
MODES
Control modes
for induction heating syste
ms may be either open loop or
closed loop.
Open-loop systems are the simpler
of the two.
In these systems,
temperature control is obtained by regulating pr
ecisely the power input to the
heating line while maintaining a fixed dwell tim
e (single-shot induction heating) or feed rate
(scanning induction heating
techniques).
By these means,
every workpiece or portion
of a workpiece
receives a controlled amount
of
energy (kilowatt-seconds).
Closed-loop control systems make use of the
electric signals developed by
1;Anon
of
Process
Control
165
PositionTemperature
proportioning
recorder/controller
control
\
C
Error
signal
from c
ontrol
slid
ewire
Servomotor
Specimen
Induction
generator
Heating coil
A
Fig. 7.8. Block diagram
illustratin
g use of
position-proportioning
control and servomotor for temperature
control (from Anon., LepelReview,
Vol
1, No. 3, 1980)
ously analyzed, and a corrective action require
d to restore the specimen temperature
to the
setpoint
is applied
through
proportional,
rate,
and
rese
t
functions.
The
output
from the proport
ioning
controller is then
fed into
a
converter and amplified to drive a servomotor
(D) to
regulate the power of
the radio-frequency induction generator.
Power regulation in the generator
can be accomplished by a thyratron bias arrang
ement employing either phase
shifting or variation of the grid voltage in
accordance with the operation of
the
servomotor
through
potentiometer.
are used to
into radio-
frequency induction
power
supplies
and
hence the
power
available to
the
induction heating coil. Basically they consist
of an iron-core transformer that
regulates power flow by controlling the magnet
ic field in its iron core. This
----------------------- Page 163---------------------166
ting:
Design,
t. This results in a low output voltage drop from the induction power supply. Conve
rsely, if the control current
is high (because of a high temperature deviation
), the core becomes saturated,
the inductance of the main winding is low,
and a small voltage drop occurs
across the main winding and
a large o
ne across the output
terminals.
INTEGRATIONOF CONTROLFUNCTIONS
Although temperature control is surely the mo
st important control aspect
of an induction heating installation,
ot
her aspects of process regulation are
also important.
These include control of pa
rt
sequencing, part
handling and
positioning, and electric demand. Often, a sop
histicated control device is used
in modern induction installations to monitor
these latter functions as well as
to carry out temperature control. The names of
some of these systems do not
indicate that they are computers, but in a b
road
sense they all perform tasks
of information handling in accordance with pr
ogrammed instructions.
Some
of the more
common
systems include the
following*:
Programmable controllers. These units were
originally designed to replace
hard-wired, relay logic control devices. They
have analog control capability
(as is needed for temperature control) and t
abular and sequential logic programs,
and
can manage other
systems.
Loop controllers. These devices can be
as single-loop or multiple-loop
units
with a shared display.
They
made
per
form
the same
functions
as analog
controllers, but can also be programmed for a
daptive control, computation,
and interactive modes with time-dependent o
r sequential setpoints.
Distributed control
systems. These de
vices are designed to locate control
and data handling at various processing si
tes with an operator's interface
at a remote
central
location.
Graphic
al
displays
of process
equipment,
trending
of process variables,
group
displays of the real-time parameters
of interrelated process
functions,
an
d
simplified alarm
tracking
and
acknowledgment are some of the unique character
istics of distributed control
systems.
Minicomputers.
These
machines
h
ave
large memories
and are used
for
sophisticated programs
for optimizing,
process modeling, scheduling, and
management planning. Personal computers are
finding a place at the lower
end of this category.
At
ose
such
as
do
the
th
the
analog
Elements of Induction
Control, and Applications
Design,
Tv
]
mon
itoring
Instrumentation
Slab(V, A, and MW)
handling
Handling
equipment
control
kW'h
~
I
F--I
metering
I
I
signal
i
I
Logging
Capacitor
switches
IAutotrans,ormerl___
_1
Process
tapehanger
"7
computer
Heater
I-Slab-
control
tracking
1~
display
Demandlimit
To and from
numerous
display
F:_t
components
Phase
balan
ce
SlabStatic
standb
y
temperature
power
control
switch
Motor
control
centers
Protective
AnnunYl
relay
ciator
system
system
From
120-kV
numerous
devices
system
-T}I
Ground
Protective
deteccircuits
tion
I
Line-to-line
faults
I
of
computer
system.
control
in
time-sharing
Surface Hardening
Surface hardening of steel parts represents
an operation in which many variables
control
final
case
depth
and
h
ardness
and
service characteristics.
A
numerically controlled (NC) system designed by I
nductoheat (IPE Cheston)
illustrates the state of the art for such app
lications.* This system can be used
for parts
as diverse as knuckle pivot pins,
differential main shafts and drive
*R. N. Stauffer, Manufacturing Engineering, Vol
78, No. 5, May, 1977,p 44.
----------------------- Page 166---------------------Fundamentals
of
Process Control
169
and
Bitt
Elements of
Induction
Design, Control, and Applications
Electric-Demand Control*
A final example of the use of process-contro
l equipment relates to the control of electric demand in induction heating proce
sses. Most commercial electric rate structures include two
component
s-energy
use and
demand.
The
energy charge is based on the total kilowatt ho
urs consumed, but
the demand
charge reflects the peak rate of energy consumpti
ily carried
lers.
DISTRIBUTED
out
by
programmable
control
CONTROL
*W. H.
Sampson, Industrial Heating,
No. 7, July, 1982,
p 10.
Vol
49
of
Process
171
Peak demand
/
m
E
Control
1 0
t m
t ~
E
a
m
m
IIIIIIIII
Illl]11]11Ill,,,
Midnight
Noon
4
4
Midnight
Time
Preset target demand level
E
-6
E
-llllll
I
IIIlll
,,,
8
Midnight
Midnight
Noon
4
4
Time
Fig. 7.10.
Comparison of elect
rical
load profiles without (left) and with
(right) demand control (from W. H
. Sampson, Industrial Heating, Vol 49,
No.
7,
system
July,
failures
and
control
system
ost
frequently
implemented is a type known
as "distributed." As
cCurdy,*
there
are two
major
distributed
control.
e:
1982,
10)
shutdowns, the
that
is m
discussed by
ideas
behind
These ar
W.
Vol
McCurdy,
53, No.
Industrial
7, 1986,
Heatin
11.
172
eating:
Design,
Elements of Induction
Control, and Applications
Broadband
level
I
Mainframe
computer
~
Broadband
modem
Broadbandcoax
Broadband
modem
Microcomputer I
Baseband
level
DataE
highway
module
Datahighway(localareanetwork)
Data-
. . ~
highway
]
E
Inductionmachine
]
module
PLC . . ~
E]
level
lIHT
Forge
system
HT system
II Finishing
ce
cell
18)
In
addition,
the communications network
often
allows
individual
controllers to communicate among themselves wi
thout intervention or direction by
a host computer.
The advantages of distributed control as c
ompared with a centralized control system (in which a master
device is
required
for operation) include the
preservation of system integrity in the case
of a (localized) hardware
failure
and a modular design which provides the abili
ty to gradually expand processing capabilities without
a major,
one-tim
e capital investment.
Induction heating cells can be tied into hig
her-level, or "broadband," plantwide systems as well as be parts of local area
networks. A
schematic of how
this can be accomplished is illustrated in
Fig.
7.11.*
The
lower part
of the
over-all network utilizes baseband
levels o
f communication. In the upper part
of the diagram, the basic
components of
a plant-wide,
broadband
network
are shown.
The
broadband
network
h
andles
large amounts
of concurrent
communications and, in large operations, can p
rovide a broad range of capabilities as well as many cost advantages. For
example, functions such as order
*G.F. Bobart,Heat
ay, 1986,p 18.
Treating,
Vol 18,No. 5, M
173
planning, production dispatch, cell control and
reporting, and direct numerical control communications are typically carr
ied out at the broadband
level.
Interfacing/Connecting
Control-System
Components
The term
"interfacing" refers to
the
means by which various
digital (and
analog)
devices are connected to
enable
communications among them.
The
connection must accommodate operating voltage d
ifferences and,
for control
devices, the hardware
and
software charac
teristics
of each device.
Hardware
considerations in typical contr
ol systems generally center on the
type of wiring or cable that
is used. At
this time there is no
standard
that is
universally accepted. As described by McCurdy
and Bobart,
however, Electronic
Industries Association Recommended Sta
ndard 422
(EIA
RS 422)
is
evolving as the
one most
often relied on
for connecting digital process controllers to each other and to computers. Usu
ally, this consists of twisted pairs
of wires that
form the
so-called data
h
ighway network.
This method,
or a
modification of it, is attractive because it
is inexpensive, it is suitable for use
in adverse plant
environments,
and
it
is "multidroppable"-i.e.,
the same
communications cable can be connected simultane
ously to
several controllers.
There is also the added advantage that
a
n RS 422 communications "port" is
easily derived from the type
found
on
most
mini- and
mainframe
comput-
e r s - an RS 232 p o r t - u s i n g a relati
vely simple active converter. The RS 232
standard,
however,
is not suitable for t
ypical plant
environments, nor
is it
multidroppable.
At the broadband
level of communications
, coaxial cables are most often
used to link higher-level system components. These
cables permit simultaneous
transmission of signals over multiple channels
.
If wiring methods were the only concern in se
tting up a control system, process design and execution would be relatively
simple. An equally if not more
important
design characteristic relates to
the
software,
or instruction package, that controls the
flow of information
.
Also known
as "protocol," this
software determines how information is sent a
nd received over the network.
This includes the
amount
of information
sent at one time,
error checking,
addressing, and information coding. There are
two basic types of communication*:
synchronous
and
asynchronous.
Synchronous communication requires that both the sender and the receiver
(for example, two computers or
one computer and a controller) have clocks whi
ch can be synchronized so that
data may be sent at precise intervals. Thi
s requires
expensive hardware,
but
allows
fast and very reliable communications
. In asynchronous communication, data are sent in an intermittent stre
am.
Such a technique is simple, but
speed is sacrificed. Asynchronous data transmissi
on is the more common technique.
*R. G. Blocks,Microprocessors
in Heat Trea
accepted
ting in
this
specification and
its further development.
are
coopera
MISCELLANEOUS CONTROLTECHNOLOGIESUSED IN
INDUCTION HEATING
With the advent of automation and the demand
for controlled-quality products, increasing emphasis
is being placed
on nondestructive techniques
for
evaluating final product properties.
Methods
which allow for real-timefeedback control of the actual induction heating
process
are of special interest.
Several of these methods, pertinent to induction
hardening processes, are discussed in this section.
ElectromagneticSorting
Electromagnetic sorting processes make use of t
he dependence of magnetic
properties
of ferromagnetic steels on hardne
ss,
case depth, microstructure,
residual stresses, etc. to verify proper heat
treatment.
These magnetic properties include permeability, coercive force, satur
ation, and remanence, each of
which relates to phenomena during magnetization,
as illustrated in Fig. 7.12.
These drawings depict the relationship between m
agnetizing force (H) and the
flux density of the field of magnetic induct
ion (B). When a virgin specimen
is used, the flux density B increases rather rap
idly upon initial application of
a magnetizing force H (Fig. 7.12a). Eventually
it reaches a point at which any
increase in H
leads to no increase in B.
The flux density at
this latter stage
denotes the saturation point.
When the magn
etizing force is reduced to zero
of
Process
Control
1
75
B is equal to zero is referred to as the co
ercive force in the material. As the
reversed field is further increased, the specim
en again becomes saturated but
in the opposite polarity.
Upon increasing
H again in the forward sense, the
remaining portion
of a closed loop,
known
as a hysteresis loop,
is formed
(Fig.
7.12d).
If the magnetizing
force a
nd
flux density are
the result
of
an
alternating current (either applied or induced
), the hysteresis loop is traced
out once for every current reversal.
The detailed hysteresis behavior itself, or o
ne of the characteristics of the
hysteresis loop, is relied on in electromagne
tic sorting for evaluation of case
depth (or average hardness).
One of t
hese characteristics is the value of the
coercive force. In practice, a probe is placed
on the test piece, and a coercive
force measurement is made. Then the case depth m
ay be read from a calibration curve previously prepared by destructive ch
ecks (i.e., metallographic sec-
B+ (fluxdensity)
B+
~ a
a
f
(maximumflux?rdensity
saturation
Ob = residual
magnetism (B,)
point)
H-
H+
H+
O
0
(magnetizing
force)
(magnetizing
force)
(a)
(b)
B- (fluxdensity)
BB+
B+
b/// a
b
a
HOc =coercive
force (Hc)
e
Of =coercive
(c)
-(d)
"I I"
force (He)
coils
Variable
arms
and
examination)
shallow
and
deep
of
samples
cases.
This
depth
by
electromagnetic means,
uses
a bridge-comparator
system. The phenomen
on which underlies this application is the fact that the magnetic permeabilit
y of a piece of steel is a function
of material condition, such as the hardness l
evel. The magnetic permeability
is defined as the ratio of B to H.
From
the hysteresis loop, it can be seen that
this ratio
can assume values up to
som
e maximum denoted by/~max.
Bridge-comparator tests rely on various typ
es of bridge circuits, nearly all
of which are modifications of the simple indu
ctance bridge (Fig.
7.13).
The
bridge includes reference and test coils which
are identical in size and number of turns.
For most applications, the b
ridge is energized by ac current at
a frequency between
60 and
1000 Hz.
Lower
frequencies are typically used
to check average or core hardness whereas hig
her frequencies are employed
to discriminate between parts
of differ
ent case depths.
When
steel components
are
used
as the
cores
of the
coils, the
over-all
impedance (or inductance) measured across each
of the coils depends on the
magnetic characteristics (i.e., magnetic permea
bility) of their cores. For identical cores, the impedance of each arm will
be the same, points P and Q will
be
at the same potential,
and the indica
tor will yield a null reading.
During
the
actual
inspection
operation,
a re
ference
component,
or "standard,"
is
of
Process
Control
177
D
epth of case, mm
0
1.0
0.25
1.25
0.5
1.5
0.75
1.8
50
I
8640
steel
40
O3
'10
3O
Q.
E
O
o
20
10
0
0
0.04
.07
Depth of case, in.
0.01
0.05
0.02
0.06
0.03
0
Resistivity
epth
Measurement
of
Case
Colorimetric
ng
Evaluation
of
Induction
Hardeni
Another,
more recently developed, nondestruc
tive inspection technique for
evaluating the results of induction hardening
operations is that referred to as
the colorimetric method.I" This test is used for
flat parts which have been surface or locally heat treated. The teeth of g
ears and bandsaw blades are typical applications.
Following
induction
har
dening,
various
microstructural
constituents
are found in the heat treated
parts. Layers at the outer surface
are usually martensitic, whereas lower-tempera
ture transformation products
are found
away
from this zone.
It has be
en noted
that regions of varying
microstructure (and hence peak temperature duri
ng the heating cycle) can be
correlated with bands
of various colors that
are formed during processing. In
turn, the extent and type of the colored bands
can be correlated with the hardness pattern produced.
PROCESS
SIMULATION
of
Process Control
179
aspects
ns and
results
Problem
equatio
Formulation
Design,
Elements of Induction He
Control,
and Applications
roblem
in numerical analysis. The
temperature dependence of the material proper
ties must be included. Several simplifying approximations
oft
en used are that the eddy-current heat
source is uniformly distributed in the sample a
t low frequencies and is localized at the surface at high
frequencies
.
Boundary conditions. Boundary conditions h
ave to be specified for both
the electromagnetic and thermal portions
of the problem.
The most difficult of these involves the heat-transfer cond
itions at the workpiece surface.
This
is primarily
a result of uncertai
nties
associated with
emissivity and
radiation
losses.
During
and
computation,
temperature
the
fields
eddy-current
are calcu-
was
simulated using the
one-dimensional (static hardening) or two-dimensional (scan
hardening) heat-conduction
equations with boundary conditions consisting
of prescribed heat
fluxes on
the workpiece surface.
Phase transformations during the heating cycl
e were calculated with the use
of isothermal transformation
(reausteni
tization) diagrams and a "staircase"
model to account for the actual continuous h
eating involved in the induction
experiments. The data were quantified using th
e expression due to Avrami~
and
Johnson
and Mehl:
Vk =
1 -- e x
p [ - b k ( T ) " t nk(T)]
*J. D. Lavers, M. R. Ahmed, M. Cao, and
S. Kalaichelvan, IEEE Trans., Magnetics, Vol
21,
1985,
p 1850.
tM. Melander,
J. of Heat
Treating, Vol 4
, No. 2, December,
1985,
p 145.
~M. Avrami, J.
Chem. Phys., Vol 7, 1939,
p 1103.
W. A. Johnson and
R. F. Mehl,
Trans. A
IME,
Vol
135, 1939,
p 416.
----------------------- Page 178---------------------Fundamentals of Process Control
181
where V k is the volume fraction of phase
k after holding
for t seconds at a
constant temperature
T, and
n k is a
constant.
The
diffusionless martensite
transformation
(on
quenching) was modeled
through the relation:
Vmartensite
[-7(M~
= 1 - exp
T) a]
where
Vmartensite
is the martensite
volu
me
fraction,
Ms
is the
"martensite
start" temperature,
and
3' and/3
are ex
perimentally determined constants.
The simulations conducted by Melander* also p
ermitted estimation of residual stresses and hardness
distributions.
Residual stresses were derived from
the stress-equilibrium equation, the flow rule,
and an assumed elastic-plastic
unloading.
Hardnesses
were
estimated
from
regression
equations
relating
Vickers hardness
of a given phase
to
i
ts chemical composition.
Several sample solutions obtained by Melande
r are shown on the next two
pages
in Fig. 7.15 and
7.16. Figure
7.
15 compares
measured and
predicted
temperature-versus-time histories
and
final hardness,
martensite,
and
axial
residual
stress distributions in a 40-mm(1.57-in.-)
diam bar.
The bar
was
heated in a single-shot mode with an
80mm- (3.14-in.-) long solenoid inductor energized by a 300-kHz power supply. Foll
owing heating, the workpiece
was
allowed to
air cool for 4.3 s and t
hen water
quenched.
The
simulation
and
experimental results
exhibit excellent
agreement.
Figure
7.16 also shows fairly good agree
ment between measurement and
prediction for a bar that was progressively h
ardened. The 40-mm- (1.57-in.-)
diam bar
was hardened with
a single-t
urn coil which was
18 mm
(0.71 in.)
wide and which traversed the workpiece at a
rate
of 3.47 m m / s (0.14 in./s).
Melander,
quenchant
ibid.
Elements
Design,
10001r=
18.6mm
I
of
Control,
I
11
830
/(73
800~
in.) A
\
/
,,~
--I
~ "
1470
/
~ "
Calculated
/
y /
Measured
~
?
,
~"
/
~
|
ou,,oopi//\\
4]--/~t/ \
~\\
I's
--
~
I-
'
1-
~ ' / r ( =
15 m~
_.1
2 o o
390
0
40
60
(a)
Time, s
20
80
Depth, in.
0
0.16
0.24
0.08
0.31
100
0.3910
00
- 7
I i
8 0 1
800
~'~
~
;
K/
>
6 0
MeasuredHV
- -r
600
Hardness
~ ~.g'
Martensite
~
C
. ~
"0
40
400
o
T
20 -~
200
%
o
I
-I---
1
2
10
(b)
Depth, mm
Depth, in.
0
0.16
0.24
0.08
0.39
I
0.31
1000
145
o
o
~
Q.
~
500-Calculated
73
-500
-73
(~
Q~
-1000
-145
.Measured
-1500
J
-218
I
-2ooo
1
I
I
-29o
0
4
2
8
10
(c)
Depth, mm
Fig. 7.15.
Measured and predi
of (a) temperature-versus-time
history,
(b) Vickers
hardne
martensite-content
profiles,
cted values
ss
and
and
(c)
in AISI
hard-
axial
4142
of
Process
Control
1 8 3
1000
1830
I
I
800
1470
r=18.6
mm (0.73
_
o
t
in.~alculated
o
600
. . . .
/
_
1110
Measured
6
(0.59
in.)
Q .
750
E
E
400
- -
I-200
390
0
0
10
20
30
40
Time,
Depth,
s
in.
0
0.16
0.08
0.24
0.31
0.39
100
1000
I
I
80
- - 8OO
I
--
~ 1
Calculated
r l
Measured
HV
>
r "
--
600
I
8
--
400
4O--
I
2 0 --
200
0
I
I
0
10
Depth,
Depth,
mm
in.
0
0.16
0.39145
0.24
0.08
0.31
1000
I
500
- - 73
I
--
0
0
Q.
-500
-73
Q)
J
Calculated
-145
-1000
Measured
-- 1 5 0 0 - -218
I
-2000
I
I
-290
I
0
2
8
10
Depth,
predicted
values
mm
Fig. 7.16.
Measured and
of (a) temperature-versus-tim
e
history,
(b) Vickors
hardness and
martensite-content
profiles,
and
(c)
axial
residual stress patt
ern
in AiSI 4142
steel samples
surface
hard-
ng technique
2,
(from
December,
In
heating
a sense, coil
is built upon
empirical
sprung
as
Fabrication
data
from
design for
a large
i
s
whose development h
theoretical analyses
of
several rather simple inductor geome
tries such as the classical solenoidal coil.
Because of this, coil design is gener
ally based on experience. The objective of
this chapter is to review the fund
amental electrical considerations in design
of inductors
and
to describe
some
of the
most
common
coils in us
e. The
actual construction of coils and t
he selection of power-supply leads are also
treated.
BASIC DESIGNCONSIDERATIONS
In
previous
chapters,
the a
a transformer
and
an
nalogy between
inductor/workpiece
combination has
been
described.
The
inductor
is simi
lar to
the transformer
primary,
and
the workpiece is equivalent to
the
seco
ndary
(Fig. 8.1). Therefore, several of
the characteristics of transformers
a
re useful in the development of guidelin
es for coil design.
One of the most important featu
res of transformers lies in the fact that the
efficiency of coupling between
is inversely proportional
windings
to the
.
ary
the
them
prim
part
the
that
rea to
be
point,
the higher will be the
current generated in the part.
2. The greatest number of flux li
nes in a solenoid coil are toward the center
of the coil. The flux lines
concentrated inside the coil, providing t
are
he
maximum
heating
rate
there.
185
----------------------- Page 182---------------------186
ction Heating:
Applications
Elements of
Design,
Control,
Indu
and
Ip
I s
Ep
Es
R E
C
N
N
P
sistance (fl).
Fig. 8.1.
Electrical circuit
llustrating the analogy between induction
heating
and the transformer
principle
3.
to
Coil Design
and
Fabrication
187
tic flux.
A pancake
coil where the flux from o
nly one surface intersects the workpiece.
An internal coil for bore heating, where
only the flux on the outside of the
coil is utilized.
Cancellation
Inductance
\
;
(
fl,
i
n
on
ill,
Design,
Elements of
Control, and
Induction
Applicati
ons
Table 8,1. Typical couplingefficiencie
sfor inductioncoils
r---Coupling efficiency at
I
10 Hz
Magnetic
steel
frequency of: 7
450 kHz
Other
Magnetic
Type of coil
metals
steel
Other
metals
in
30
mind.
s but
If
a
one pa
50-s h
eating
time
is required,
it is necessary t
o
heat
parts
in multiples to
meet
the
desired production rate.
Keeping these co
ncurrent needs in mind, it is important
to look at a wide range of coil tech
niques to
find the most appropriate
one.
BASIC
COIL
DESIGNS
Low-Frequency Heating
Low-frequency induction heating is generally
desired for through heating
of metals,
particularly those with large a
nd relatively simple cross sections.
Typical
applications
are
round
or
round-cornered
square
(RCS)
stock
for
forging or extrusion and
slabs
for h
ot
rolling.
In
these cases,
coil design
is
often quite simple, usually consisting of a sol
enoid coil or a variation of it that
matches the basic workpiece cross-sectional s
hape (e.g.,
square, rectangular
trapezoidal,
etc.).
Low-frequency coils often have many turns
.
Accordingly, the coil usually
forms
the
total tank
inductance,
an
d
an
autotransformer
may
be
used
to
match the high coil impedance to that of the
induction generator. In any case,
----------------------- Page 185---------------------Coil
Design
and
Fabrication
189
(c)
(d)
Fig. 8.4. Typical configurations
for induction coils: (a) multiturn, single place; (b) single-turn, single
-place; (c) single-turn, multiplace; (d) multis,
solenoid coils,
of them,
are
as
also
well as v
often rel
on
in
medium-to-high-frequency applications
such as heat treatment.
Th
ese
include single- and multiple-turn types. Figur
e 8.4 illustrates a few of the more
common
types
based
on
the
solenoid
design.
Figure
8.4(a) is a multitur
n,
single-place coil, so called because it is gene
rally used for heating a single part
at a time. A
single-turn,
single-place c
oil is also illustrated
(Fig.
8.4b).
Figure
8.4(c)
shows a
single-turn, multipla
ce
coil. In this design,
a single t
urn
interacts with the workpiece at each part-heat
ing location. Figure 8.4(d) shows
a multiturn,
multiplace
coil.
*A computer
program that can be used to cal
culate the required coil turns,
tank-circuit
capacitance, and transformer
ratio for load mat
ching and circuit tuning is given in Appendix D of S. L.
Semiatin and D. E.
Stutz, Induc
tion Heat
Treatment of Steel, ASM, Metal
s
Park, OH,
1986.
----------------------- Page 186---------------------190
on
Heating:
ons
Design,
Elements
Control,
of
Inducti
and Applicati
More
often than not,
medium-to-highfrequency applications require
specially configured or contoured coils with the
coupling adjusted for
heat uniformity. In the simplest cases, coils are bent
(a) Round
gular
(b)
Formed
(c)
(d)
Pancake
al-helical
Rectan
(e) Spir
Internal
(f)
and
Fabrication
191
0
9
()
Area to
be
(b)
hardened
(a)
/
Coil(C)~~
in po
>
,,
r
0
Coils
OD
to
approach
the
part
(at 450 kHz)
0.16
cm
(0.062
in.).
sho
In
Fig.
8.7(a), for example, the coupling dista
nce is too great;
coil modification
improves the design, as shown in Fig.
8.7(b).
Here, the coil tubing has been
flattened to reduce the coupling distance, and
the coil OD has been increased
to reduce the
spacing from coil to
wor
k.
More turns,
or a finer pitch on an i
nternal coil, will also increase the flux
density. Accordingly, the
space between
the
turns
should be
no more than
one-half the diameter of the tubing, and the
over-all height of the coil should
not exceed twice
its diameter.
Figures
8.7(c)
and
8.7(d)
show
special coil
----------------------- Page 188---------------------192
eating:
Design,
Elements of Induction
Control, and Applications
Toodeep
Keepclose Flattubing
nimum(
1 I
H
Mi
~ ~
~ m a ~ ~ .
(a)
(d)
( e ~
: 0
~h
squar
25.4mm(1i
n.)
3.2-mm(1/ain)squar
etubingfor
induction
coil
Fig. 8.8. Schematic
illustration of
induction-coil design for surface
hardening of trunnion cups
----------------------- Page 189---------------------Coil Design and Fabrication
193
lizing 60 kW of power. Because of the high current
s utilized during the heating
cycle as well as the heat radiated
from the
workpiece surface, more cooling
than can be obtained using the normal coil wa
ter supply is required here. In
a case of this nature, it is best to provide
a separate, high-pressure water supply for the coil to achieve a satisfactory fl
ow rate.
COMMON
Coil
DESIGN
MODIFICATIONS
Characterization
Design,
Elements of Inductio
Control, and Applications
Path of windings
narro
wer
at small end
Paralle
l
I~:ii,
!iii~. . . . . . .
"
(b)
::.
(:E
~ D
-"
Coil
is para
llel
,oax,
(c)
Variation
in coupling
- O
-O
(d)
should be used.
If part rotation is not feasible, heating un
iformity can be increased by using
flattened tubing, by putting an offset in the
coil, or by attaching a liner to the
coil. Flattened tubing
should be plac
ed
so that
its larger dimension is
adjacent to the workpiece. The offsetting of coil tu
rns (Fig. 8.10) provides an even
horizontal heating pattern.
Offsettin
g is most easily accomplished by annealing the coil after winding and pressing it betw
een two boards in a vise. A coil
liner is a sheet of copper which is soldered o
r brazed to the inside face of the
----------------------- Page 191---------------------Coil Design
and
Fabrication
1 9 5
) J
)
C
C
Fig. 8.10. Induction
coil
ffset used to provide heating uniformity
with an o
is
Design,
Elements
of Induction
Control, and Applicatio
ns
5.1-cm- (2-in.-) ID coil should have a
1.91-cm (
0.75-in.) maximum height, and
a 10.2-cm- (4-in.-) ID coil should have a 2.5-cm
(1.0-in.) height. Figure 8.13
shows some typical ratios.
Coupling Distance. Preferred coupling distance de
pends on the type of heating
(single-shot or scanning) and the type of materia
l (ferrous or nonferrous). In
static
surface heating,
in which the p
art
can be
rotated
but
is not
mov
ed
through the coil, a coupling distance of 0.15 cm
(0.060 in.) from part to coil
is recommended. For progressive heating or scann
ing, a coupling distance of
0.19 cm (0.075 in.) is usually necessary to al
low for variations in workpiece
straightness. For through heating of magnetic mat
erials,
multiturn inductors
Coil leads
Connection from generator to
coil (braze points)
Coil liner
Tubing soft soldered to
J
coil liner for maximum
surface-to-surface
Top view
cooling
Side view showin
g actual shape of coil
a
liner
Fig. 8.11.
in a
coil to
Method of inserting
widen the flux path
Design
and
Fabrication
197
89-mm
)
,
I
\
I
I
,
~--I--I
~1
(a)
1'
,,
Gear
Coil
i,i
I
I
I
I
I
I
t
I I
I
I
I
(b)
Single turn,
Multiturn,
bad
good
(c)
'1
I
- ~
I
,,
, / , ,
II
'
Coil
(d)
1_
Gear
Locating stud
Spray-quench
ri
ng
Fig. 8.12.
e-turn vs. multiturn
the
Selection of singl
coils depending on
f the workpiece
h Fre-Hill,
length-to-diameter
(from F. W.
ratio o
Curtis, Hig
---198
ction
Heating:
Applications
Elements
of Indu
Design,
Control,
and
12.7mm
(1/2in.)
25.4mm
I
12.7mm
I
" ~ '
I
('/2 in.)
51mm
(2in.)
I
I
1"~mm
(%in.)
coo,,
102
m m
2 i412;I
(4in.)
Fig. 8.13.
Typical proportions of
various single-turn coils (from F. W.
Curtis, High FrequencyInductionHeat
ing, McGraw-Hill, New York, 1950)
thick
ll as
refractory
electrical
materials,
insulation,
as
must
we
be
nal
eddy-current path
is produce
d which
will cause heating
at
a rate
consid
erably higher than
that
in the
rest
of the
part.
The addition of a copper slug to the
hole can be used to effectively cor----------------------- Page 195---------------------Coil
Design
and
Fabrication
199
When the coil overlaps the
edge (left), overheating will occur
on the end surface. Coil place
ment should be slightly below the
edge (right) for a more uni
form heating pattern.
Fig. 8.14.
Effect of coil pla
cement on the heating pattern at the end
of a workpiece
(from F. W. Cur
tis, High FrequencyInduction Heating,
McGraw-Hill, New York, 1950)
Keyway
Fig. 8.15.
Localized overheating
of sharp corners, keyways, and holes
most prevalent in high-frequency
induction
heating (from F. W. Curtis,
High FrequencyInduction Heating, Mc
Graw-Hill, New York, 1950)
----------------------- Page 196---------------------Heating:
Design,
Elements of Induction
Control, and Applications
The pos
can con-
trol
the resultant
heating pattern.
In
addition,
the slug will minimize hole
distortion if the part must be quenched foll
owing heating. For
slotted parts
heated with
solenoid coils (Fig.
8.17),
the continuous current path
is inter
rupted by the slot, and the current must th
en travel on the inside of the part
to provide a closed circuit. This is the basi
s for concentrator coils, which are
discussed below.
It is of interest to no
te, however, that with the slot closed,
the applied voltage of the work coil causes
a higher current to
flow. This is
due to the fact that the resistive path,
now around the periphery of the part,
is considerably shorter. The increase in current
then produces a considerably
higher heating rate with the
same coil.
----------------------- Page 197---------------------Cog
Design
201
and
Fabrication
I ~
Mu/litiyrn I ~
~
~
Fig. 8.17.
Localize
d overheating of slots
in
certain
parts that
results
from the tendency for in
duced currents to follow the part contour (from
F. W. Curtis, High Frequen
cyInductionHeating, McGraw-Hill,
New York,
1950)
Flux
e
Diverters
When two
are to be
separate
heated,
regions
but
of
workpiec
are close
together
(Fig.
8.18),
i
t is possible that
the
magne
tic
fields of adjacent
coil
turns will overlap, causing the entire bar to be
heated. To avoid this problem,
successive turns can be wound in opposite dire
ctions. By this means, the interHeat
i
Fig. 8.18.
Control
of
heating
patterns
in t
wo
different
regions
of
a
werkpiece
by win
ding the turns in opposite
directions
(from
F. W. Cur-
tis,
tion Heating, McGraw-Hill,
New York,
Design,
Elements
Control,
of Induction
and Applicati
ons
mediate
fields will
cancel,
and
the
fields that
remain
will be
restricted.
It
should be noted that,
as shown in Fig.
8.18, lead placement is critical. Having the return
inductor
spaced far
f
rom the
coil leads would
add unneeded
losses to
the
system. Another
example
of a counterwound coil is shown in
Fig.
8.19; the coil in Fig.
8.19(b) is the
counterwound version of the one in
Fig.
8.19(a).
This type
of coil can b
e
used
effectively in
an application i
n
which the rim of a container is to be heated
while the center remains relatively
cool.
Another technique that can be utilized in t
he above circumstances involves
the construction of a shorted turn or "robber
" placed between the active coil
turns.
In this case, the shorted loop acts
as an easy alternative path
for c
oncentration of the excess flux, absorbing the
stray field. It is therefore sometimes called a flux diverter. As
for t
he active coil turns,
the robber
must
be
water
cooled to
dissipate its own heat.
Figure
8.20
shows
typical
installa-
Design
and
Fabrication
203
s"
ng
as required.
These can be shorted with a
copper strap
or temporarily brazed
while tests are made, and removed pending the
outcome of the heating trials.
"Balancing" of
r
Multiplace Coils
Interaction between
to
be considered when
coils
is a facto
constructing
ct the path
of the current
as shown i
n
Fig. 8.23(c).
It should also be noted th
at to provide uniform heating at the
end position, additional saw cuts, simulating t
he lead locations on the interior
coil positions,
should be made
on the
two
outer locations.
Once coil balance
has been
achieved
, water
cooling can be
accomplished
by brazing or soldering formed tubing to the
plate coil, as shown in Fig. 8.24.
Plate coils need not be used
solely
for heating of parts with similar diameters and masses.
It is desirable in som
e instances to heat a number of parts
of different sizes and shapes simultaneously.
The problem then becomes one
of establishing a balance so that all parts co
me to the same temperature at the
----------------------- Page 200---------------------204
Heating:
Design,
Elements of Induction
Control,
and Applications
t
~-~
Water
path
Braze
of
construction
)
----------------------- Page 201---------------------CoilDesign
and
Fabrication
205
.~ads
. ~ [ ~
Poor
(a)
1
L
L_
(b)
_J
t
Goo
d
Sawslots
(c)
Be
st
Fig. 8.23. Design of multiplace induct
ors (from F. W. Curtis, High Frequency Induction Heating, McGraw.Hill
,
New York, 1950)
same time. An
example of how this is ac
complished is shown in Fig.
8.25.
Once the coil is fabricated, balance is achieve
d by opening the coil coupling
in those areas that heat the fastest, thus d
ropping the heat level in these locations until the pattern
is uniform.
Multiplace coils may be of both plate and
tubing types. Plate coils provide
COILS
o
t
Design,
Elements of Induction
Control, and Applicat
ions
Leadsto
~ . ~
generator
I
i
I
I
Work
Coils
and
Coil
Inserts
required
ld be
heating
pattern
and
shou
Design
and
Fabrication
207
Leads to
power source
-"'L
\
Braze
F Holes for
bracket
0
-ill
@
II
0
__jj
~ ,
Cover
Body
'
I
Water cooling
S
ection through
heating area
Fig. 8.25.
Design of a sin
gle-turn, multiplace
inductor for simultaneous
brazing of different-size
cou
plings in o single operation (from F. W. Curtis, High FrequencyInductionHe
ating, McGraw-Hill,
New
York,
1950)
somewhat greater in thickness than the depth o
f the recess for easy removal.
Special coil shapes are easily configured. It
is important to note that, because
of the less-than-optimal cooling technique,
coil inserts are
particularly
well
adapted to processes requiring short heating t
imes or those in which they are
also cooled by the
quenching med
ium.
In machining of coil inserts,
care must be taken to
relieve sharp
corners,
unless it is desired to
have
a deeper heating pattern
i
n these locations.
Figure
8.28
shows the
effect of
sharp
corners
on
a closely
coupled part.
Flux
from both inductor sides couples to the corn
er, which, due to a lack of mass,
tends to
overheat relative to
the rest
of the pattern.
Decoupling of the
coil
from these locations provides the desired patte
rn but tends to reduce over-all
efficiency, thus slowing the heating rate and
resulting in a deeper case. Relieving or decoupling of only the corners is a be
tter alternative, particularly when
a
solid inductor is used,
an
d the relief can be machined
as required.
----------------------- Page 204---------------------208
Heating:
Elements
of Induction
Control, and Applications
Design,
Leadsto
generator
A
Tapped holesfor plasticsheet
. , ~
/
Plast
ic
~
, /
plat
e
ring
~
. , ' ~ / ~ f
i
Tube
~
, ~
I L
~
]
/ /
o,;
Fig.8.26. Single-turn,multiplaceinduc
torwith individualcoilsof copper
tubing (from F.W. Curtis,High Frequenc
yInduction Heating, McGrawHill, New York, 1950)
_ 1
"
, ,
Water
Fig.8.27. Schematicillustration showi
ngthe designof a mastercoil
with changeableinserts (from M. G. Loz
inskii,Industrial Applications
of Induction Heating, PergamonPress, L
ondon,1969)
----------------------- Page 205---------------------Coil
Design
and
Fabrication
2 0 9
Coils
for
Induction
Scanners
of design.
the upper,
Cooling
water
flows thr
or inductor,
cham-
Induction Heating,
Pergamon Press, L
ondon, 1969)
----------------------- Page 206---------------------210
ents
ng:
of
Induction
Design,
Control,
Elem
Heati
and Applications
Inductor
Heating
!!!
Quench
ring
Quenching
(a)
f -
Inductor
,
Quench
ring
LI-
.I
L-i
'
(b)
Fig. 8.29.
In
ductor/quench designs for induction
scanning: (
a) separate
coil and quench and (b
) two-chamber,
integral
coil and quench (from
F. H. Reinke and W. H. G
owan, Heat Treatmentof Metals, Vol 5, No. 2,
1978,
p
39)
----------------------- Page 207---------------------Coil Design and Fabrication
21
ber to
keep the copper resistivity low.
quenchant is sprayed from perfo-
The
Coils
.
Clamps are used to
ensure closure during heating.
Often, high currents a
t high frequency pass through this
interface, and the life of the contact is gen
erally limited due to both wear and
arcing.
Coolant for the coil chamber of a split in
ductor is carried by flexible hoses
that bypass the hinge so that excessive heatin
g does not occur in the movable
section
during
the
cycle. The
quench
ch
amber
is fed by
a separate
hose
arrangement.
The face of the quench cham
ber is closest to the work during
heating,
and therefore
carries most
of t
he current.
Accordingly,
it must be
sufficiently thick to
preclude either melting
or distortion during the heating
cycle.
With
split coils it is also frequently n
ecessary to provide
some means
of
locating the part in the coil to maintain the
proper coupling distance. Ceramic
pins or buttons are frequently secured to th
e face of the inductor. These pins
contact the part during the heating cycle and es
tablish rigid relative positioning
between part
and coil. However,
they are
subject to thermal shock during the
heating and quenching cycles and suffer mechanic
al abuse as well. Therefore,
they
should
be designed
for simple
repl
acement
as required.
Figure
8.32
depicts an arrangement for the use of either
ceramic or metal pins that
compensates for these problems. Here,
the c
eramic pin is approximately 0.64 cm
----------------------- Page 208---------------------212
Elements
of
Induction
eating:
Design,
Control,
and
Applications
use
th
Coils
When transformers
are not
available
or when extremely high power
densities are required, it is sometimes necessary
to utilize an induction coil as the
secondary of a current transformer. That is to
say, the turns of a primary coil
are used to induce high currents in a copper
("concentrator") secondary that
is connected to,
or serves itself as, the
coil which heats the workpiece.
For
instance, when a complex assembly must be h
eld in a fixture for brazing,
it
is sometimes simpler to have each fixture inc
lude its own coil and inductively
couple the
energy to the
coil.
Figure
8.33 shows an
example in which
a multiturn pancake
coil is connected to the
power
supply and in turn
work
and
Fabrication
213
f
/I
(I
(a)
(b)
Fig. 8.31. Diagram (a) and schem
atic illustration
(b) of a split
inductor
used for heating crankshaft jour
nals
(from M. G. Lozinskii, Industrial
Applications of Induction Heating,
Pergamon
Press,
London, 1969)
secondary, and the current is forced to tr
avel through the active portion
of
the coil to
complete its return path.
In operation, the secondary/coil combination is mounted to the fixture and the sec
ondary passes beneath the primary
pancake coil as the combination moves on a
conveyor. Heat
is genera
ted in
the workpiece as the
secondary passes
through the flux field of the primary.
In Fig.
8.34, the transformer secondary mov
es through the primary.
The secondary, inside the major
flux field
of the primary,
couples energy to the
coil
even while it is in motion. This is an ideal
way to energize the coil while providing reciprocating motion.
----------------------- Page 210---------------------214
tion
Heating:
plications
Elements
Design,
Control,
of
Induc
and Ap
4
i
/j
[
~...............I
~............ ~,
...~
\ \ ~ J
~ _ ~
..........
\ \
5-IIl111111
I
II 11II
II
n1111111
II
I
(a)
(b)
ceramic
Fig. 8.32.
Design of metal and
pins for fixing the position of
a split inductor
on
a cranks
haft
journal (from M. G. Lozinskii, Indus.
trial Applications
of Induction H
eating, Pergamon
Press, London, 1969)
Top view of plate secondary
plate
Mov,ngIIr
secondary
Statio
nary
prima
ry
induct
ion
coi
l
Object
being
k
L - n
of
Corp.)
Fabrication
215
Reciprocating
secondary
Primaryturns
i<
oi
l
Fig. 8.34. Schematic
f a movable secondary concentrator
inductor
illustration o
ooooo
/ / / / / i / / I
Plate-type
J
inductioncoil
J
Copper
case
Fig. 8.35. Schematic illustration o
f a concentrator-type
induction coil
used for
induction
soldering
(s
ource: Lepel Corp.)
----------------------- Page 212---------------------216
on Heating:
to
melt
of bars
cial
Design,
Elements
of Inducti
Control, and Applications
powders.
Butterfly
Coils
Circular
(a) and
slot
ted
(b) concentrator
coils; arrows
indicate direction of current flow (f
rom E. May, Industrial High Frequency
Electric Power, Wiley,
New York
,
1950)
----------------------- Page 213---------------------Coil
Design
and
Fabrication
2 1
7
Split-Return
Inductors
If
a
and
narrow
band
of heat
is requir
ed
heating
must
be
accomplished
from
one
surface only as
in weld-seam a
nnealing,
the split-return inductor
offers distinct advantages (Fig.
8.39).
With this design, the center runner
of
the work coil carries twice the current of each
of the return legs. The pattern
on the workpiece, being a mirror
ima
ge of the coil, produces
four times
as
much heat under the center leg as in each
of the return
loops.
With proper
balancing,
the high-heat path
can the
n be
extremely narrow
while the heat
produced in
icient to
the part.
Tapped
each
Coils
with taps
is
the
to
a for
end"
of
a bar,
in which
ade
to adjust
provision must
the length being
be
m
heated
Elements of
Design,
Control,
Induction
and Applic
ations
/
/
(a)
on
of
type
a
of
illustrati
construc-
Coils
Design
and
Fabrication
219
ings
along the
length
of
the
strip which
indu
~
I
I l l l
IIIII
~
f
Fu!l
in ce
nter leg
Inducededdy ~
~
currents follow ~
o
I
(a)
parallel to coil
_ I
~
currents
I
and
are
most intense
I
/f~"
I ol
I"1\
I ~1 L~\
I ~1 ~ " ~
I
under center leg
I
I
,N
/L~
Y /
v
Return circuit for
Sprocketwheel
~
~ , ~
.
/ /
eddy currents spread
~.~'/
over two relatively
/ / ~
large areas
//
'~lduCedeCUrrg~tt~enOt
~ l
/ /
for materialto reach
/
~
hardeningtemperature
"
= ,
J l l o J
(b)
Area to be
hardened
Elements of
Induction
Heating:
Design,
Control,
and
Applications
Coil
Construction
However,
extreme
co
care must be
current
from
osest to
taken
going
the
cl
Design
and
Fabrication
221
(a)
(b)
Fig. 8.41. Illustration (a) of on
e type
of
transverse coil for heating a
thin section;
sketch in (b) in
dicates the current path
in the workpiece
(from F. W. Curtis, High Frequenc
yInductionHeating, McGraw-Hill,
New
York, 1950)
The best method
for parallel
coi
l construction makes use of a wide
bus
arrangement, as shown in Fig. 8.42. With iden
tical coils mounted to the bus,
this method
permits
rapid,
simple
replacement
of
individual
section
s
as
required, and fabrication of the individual se
ctions is easily accomplished. A
second technique, which ensures an even current
distribution, comprises the
interwinding of several coils as shown in Fig.
8.43. Here, an even current distribution
is ensured in that
its
in
Tuning
Stubs
same point
(Trombones)
Design,
Elements
Control,
of
and
Inductio
Applicat
lower
operation
coil voltage,
is performed
beca
Design
and
Fabrication
223
Fig. 8.44. Photograph illustrating
trombone adjustment on parallel
coils
as used in epitaxial deposition (
source:
Lindberg Cycle-Dyne, Inc.)
the
heating
pattern
of each turn
indi
vidually in
order
to achieve balanced
heating.
An adjustable inductance or trombone is also u
sed in those instances where
a coil is overcoupled. In such a case, the
coil tries to
couple more energy to
the
part than
the machine
can
supply
,
thus
overloading the
system.
Even
efficient method,
the coil, a trom-
Design,
Elements of
Control,
Induction
and Applic
ations
Fig. 8.45. Photographof a typical tu
ning stub or "trombone" (source:
Lindberg Cycle-Dyne,Inc.)
nique,
in which the part
is at rest i
n the coil during the heating cycle, the en
ds
of the
hairpin
can
be
decoupled
t
o prevent
overheating
of the
ends.
These
raised portions
or bridges
also
facil
itate passage
of the part
through
t
he coil.
When
a wide
heating
zone
is to
be produced
on
the
part,
coupling
over
a
greater
area
can be
effected through
the addition
of
a liner to the
co
il turn
(Fig.
8.47), or more ampere turns can also
be produced with a multiturn channel inductor
(Fig.
8.48).
Channel-coil
liners may also be
configured to
produce specialized heating patterns
wh
ere greater heat
densities are required
in
specific areas
(Fig.
8.49).
During design of heating operations utili
zing channel coils, there is a "fill
J
Coil
J
(,-J
r
__
Work {
Bend
L_J
!
I
I.
d to
of
-
vent overheating
of ends (from
F. W. Curtis, HighFrequencyInduction
Heating, McGraw-Hill,
New Yor
k, 1950)
----------------------- Page 221---------------------Coil
Design
and
Fabrication
225
Togener
ator
Liner
~
Fig. 8.47. Use of a
liner on a
single-turn channel coil to provide a wider
heating pattern on the workpiece
(from F. W. Curtis, High Frequency
Induction Heating, McGraw-Hill,
New York,
1950)
factor" which must be considered from an eff
iciency standpoint. The unused
portion
of the coil appears
as lead
losses. Therefore, parts
must be as c
lose
as possible to each other, without touching,
to utilize the full capabilities of
/
Fig. 8.48. Multiturn channel coil
used to increase the ampere turns coupled to an induction heated workp
iece (source: Lindberg Cycle-Dyne Inc.)
----------------------- Page 222---------------------2 2 6
Heating:
Design,
Elements
Control, and
of Induction
Applications
Solder rin
g
,
,/0\I,
(;)
j ~
Leads
Condenser can
Channel
type coil
FABRICATION
0
Q
Q
Q
Direction of travel
ng
pattern
of the
heati
Design
and
Fabrication
227
Selection
of
Tubing
In addition to
the I2R loss due to its
own resistivity, the coil surrounds the
load and absorbs additional heat through radi
ation and convection from the
heated surface. Therefore, it is essential tha
t the tubing selected for the work
coil have a sufficient cooling path to remove
this heat.
Otherwise, the resistivity of the copper will increase due to the te
mperature increase, thus creating
greater coil losses. In some instances, such a
s large coils, it may be necessary
to
break
up the individual water paths
in a coil to prevent
overheating and
possible coil failure. Figure 8.51 shows a
coil used for a line-frequency application which has a number of manifolded water
paths to prevent steam formation.
Another factor in the selection of tubing
for induction coils relates to the
fact that the current in the work coils is t
raveling at a specific reference depth
which depends on the power-supply frequency a
nd the resistivity of the copper.
Accordingly, the wall thickness of the
coil tubing
should be selected to
reference-depth limits similar to those used
for induction heating of copper.
Suggested wall thicknesses
for various
frequencies are
shown in Table
8
.2.
However, copper availability must be considere
d, and
often wall thicknesses
less than twice the reference depth are used
with only a nominal loss in overall coil efficiency. In coils for low-frequency
operation, particularly those used
at 60 Hz,
the large depth
of penetratio
n requires tubing with
a particularly
heavy
wall.
Because
the
current
flows
on
the
ID
face
of
the
coil
(i.e.,
for such
of
adja
applica
for
Design,
Elements of Induction
Control, and Applic
of
copper tub
Theoretical
Typical
wall
wall
thickness
available,
Frequency
m m (in.)
thickness (= 2 x
Minimum tube
reference depth)(a),
diameter(b),
m m (in.)
m m (in.)
60Hz
. . . . . . 16.8 (0.662)
14.0
(0.550)
42.0
(1.655)
180 Hz
. . . . . . . 9.70 (0.382)
8.13 (0.320)
24.3
(0.955)
540 Hz
. . . . . . . 5.59 (0.220)
4.67 (0.184)
14.0
(0.550)
1 kHz
. . . . . . 4.11 (0.162)
3.43 (0.135)
10.3
(0.405)
3 kHz
. . . . . . 2.39 (0.094)
1.98 (0.078)
5.97
(0.235)
10 kHz
. . . . . . 1.32 (0.052)
1.07 (0.042)
3.30 (0.130)
450 kHz
. . . . . . 0.15 (0.006)
0.89
0.89
(0.035)
0.38 (0.015)
1 MHz
. . . . . 0.08 (0.003)
(0.035)
0.19 (0.0075)
(a) Resistivity of copper assumed to
10-6 fl.cm (0.66 x
10 -6
be
1.67
[2.in.).
(b) Tube ID requirements
r adequate
cooling-water flow should
also be considered.
fo
heavy,
edge-wound
copper
with
a
brazed
cooling
path
at the
outer
edge to
reduce
cost.
Specially drawn
tubing
(Fig.
8.52) is also available with
an
offset extruded
cooling
path.
Square copper tubing
is also comme
rcially
available and
is frequently
used
in coil fabrication.
It offers a conside
rable
advantage
in that it couples
more
flux to the part
per turn
than round
tubing
(Fig.
8.53).
Moreover,
it
is more
easily fabricated
in that
it
will not
collapse
as readily
on
bending.
It
is also
easily mitered
(Fig.
8.54)
to create
sharp,
close bends
as required.
If only
round
tubing
is available,
it can be
flattened
in a vise or other
simple
device
(Fig.
8.55) to
adjust
the
resultant
t
hickness
dimension.
This
flattening
can be
done
with
minimal
decrease
in dime
nsion
of the
water-flow
path.
Coil
Forming
In fabrication
of copper
coils,
it must
be
noted
that
the
copper
work
hardens
with
increasing
deformation.
Thus,
most
fabricators
anneal
t
he tubSide of
path
/ / / / / / / / / / / / / / , I
ed
in
us
Design
and
Fabrication
229
ing every few bends to relieve this condition
by heating the tubing until it is
bright red, then cooling it rapidly in water
.
These intermediate anneals prevent
fracture of the tubing
during
fabrication.
In some forming operations,
it
may be desirable to
fill the coil with
sand
or salt to preclude collapse of the tubing.
In addition, there are several low
temperature alloys (with melting points below
100 C or (212 F) that are n
or-
of
Coils
to
Power-Supply
Le
Fig.8.53.
Comparativeheating patte
rns produced by using round vs.
square tubing for a solenoid inducti
on coil (from M. G. tozinskii, Indus.
trial Applications of Induction Hea
ting, Pergamon Press, London, 1969)
----------------------- Page 226---------------------230
Elements
o f Induction
Heating: Design, C o n t r o l , and Applicatio
ns
t
45
45
1
ii
i
ii
i l l
i
IL
ng to
in filling pinhole
leaks, but
will not
fill the water
path
in brazing
of sma
lldiameter
tubing.
Most
power-supply
terminals
util
ize rather
large tubing.
Thus,
it is
frequently necessary to join
small-diameter
tubing to larger tubing at some point.
Figure 8.56 shows a simple technique for acco
mplishing this. The larger tubing
is crimped
after inserting the
smaller-d
iameter
stock,
and the joint
is clo
sed
n
tubing
Design
and
Fabrication
231
To
suit
connectors
9.5
mm
(%
in.)
Braze
Tube
nuts
I
4.8
mm
(3/16
/
\
/
Sque
eze in vise
\
11
I
Harness for
leads
Coil
Bra
ze
(% in.)
1
Coil
to
suit
Fig. 8.56.
method for joining small- to
(source: F. W.
New
Illustration
of
large-diameter cop-
York,
by brazing.
The illustration also depi
cts the common use of a flare or compression
fitting when
making
coil
connections;
these
are
generally
limited
to
low-power,
high-frequency
(RF)
coils.
Although
useful
when
coils
are
changed frequently, such fittings are subject
to water leakage under constant
changing.
In
addition,
the twist
ing imparted to
the
coil duri
ng attachment
tends
to
distort
the coil configuration.
Most low-loss fishtail leads (discussed be
low) utilize solid block connectors
that
are cross-drilled for water
flow and are mated with counterbored hol
es
and "O" ring seals. In these cases, the coil
is often held to the output terminals
by brass
or phosphor-bronze
screws. This type of construction permits
coil
changes while preventing bending of the coil
during installation (Fig.
8.57).
Bracing
Because
of
Coils
electric
currents
low
in
both
coil,
the
workpiece
and
the
magnetomotive
forces between
th
e
two
are
developed.
The
ma
gnitudes
of the
forces
depend
on
the
magnitudes
of the
currents.
If
suffici
ently large,
the
forces may cause the part
to
move in the coil.
If the part
has
a large mass,
however, the coil will tend to move relative
to the workpiece. The turns may
----------------------- Page 228---------------------232
Heating:
Design,
Elements
Control,
of Induction
and Applicati
ons
Fig. 8.57. Multiturn coil showing
fishtail-lead construction (source:
Lindberg Cycle-Dyne,
Inc.)
also tend to move relative to
each oth
er,
it is important,
therefore,
that
the
coil turns be suitably braced to prevent move
ment and possible turn-to-turn
shorting. Furthermore,
coil motion rela
tive to the part
must be prevented to
avoid
undesirable changes in the
hea
ting pattern.
Much of the acoustic noise generated during
low-frequency operations also
occurs
due
to coil vibration,
much
as a speaker
coil and
magnet
struct
ure
work in an audio
system. Bracing and ph
ysical loading of the coil to restrict
Design
and
Fabrication
23
Plastic
4
(a)
J(o)
--
(b)
Cutoff
Cement
i
Braze
Glyptal
Co)
~ ( : ~ )
Screw
(c)
Fig. 8.58. Typical
techniques for
bracing of induction-coil turns (from
F. W. Curtis, High FrequencyInductio
nHeating, McGraw-Hill, New York,
1950)
withstand the voltage between the mounting studs
or the turn-to-turn voltages
of the
coil. This
is of particular
conc
ern when using high-voltage RF
c
oils
where up to
12,000 V may be impressed acr
oss the total coil.
It may be necessary in these instances to provide slots betwee
n the stud locations in the insulator boards to increase the creepage path bet
ween the studs. It may also be
necessary to increase the heat-resistant charact
eristics of the insulation by facing the area exposed to
the heated surface
with a sheet of high-temperature
insulation.
For purposes
of rigidity, cleanness,
and protection,
it is sometimes desir
Design,
Elements of Induction
Control, and Applications
LEADS
Considerations
tance
of the
leads
(LI plus L3),
a
maximum of
10% of the total voltage wil
l be lost in the leads. Any loss less
than
this can
be considered nominal.
----------------------- Page 231---------------------Coil
Design
and
Fabrication
235
Fig. 8.60, Photograph
of a
b
illet-heating induction coil that has
been
mounted
in
a
cast refractor
y for purposes of bracing
(source: American
Induction
Heating
Corp.)
Coils for low-frequency applications often
have many turns,
a large
crosssectional area, and thus fairly high inductanc
e. Hence, the comparative lead
inductance is small. As the
frequency
increases, coils often become smaller
in size, and their inductance and inductive rea
ctance decrease. As the distance
between the heat station and coil increases, t
herefore, these lead inductances
can become critical.
Several coil designs which illustrate the eff
ect of lead design are shown in
Fig.
8.63 and
8.64.
In Fig.
8.63(a),
a coil with
leads
far
apart
is de
picted.
The space between the leads
presents an in
ductance almost equal to that
of
the coil. Thus,
a major portion
of
the voltage will not
appear
in the
work-
Design,
Elements
Control,
of Inductio
and Applicat
L1
ET
L21
L3
Fig. 8.62. Schematic
circuit di
agram
indicating the inductance
of
the
coil
leads
and
induction coi
l
itself: Li,L3-1ead inductances; L2-induction-coil inductance; Cl-tank
ca
pacitance;
Ex-tank
voltage
ing area.
A better
design (Fig.
8.63b)
minimizes this gap and thus improves
heating efficiency. Figure
8.64 also
shows
single-turn, multiplace coils with
an
extremely poor
and
an improved lea
d design.
Another factor to
consider is the interact
ion of the leads with nearby metal
structures. Because all leads have some inducta
nce, they can act as work coils.
Thus, a conductor placed within their field w
ill be heated.
Leads placed adj
acent to metal structures will tend to heat th
em.
In addition to unwanted heat,
this loss reduces the power available to the
load.
It is important that lead-to
lead separation be minimized and proximity to
metallic structural members
be considered. Whenever possible, duct housin
gs, trays,
or conduits must b
e
of low-resistivity or insulating materials,
such as aluminum or plastic.
(a)
(b)
spacing
Fig. 8.63.
Effect of coil-lead
on
lead
inductance; closer
spac
ing,
as
in (b), reduces lead
inductance and thus power
losses
(from
F. W. Curtis, High FrequencyInduct
ion Heating, McGraw-Hill,
New York,
1950)
----------------------- Page 233---------------------CoilDesign
and
Fabrication
237
Typical Lead Design
Induction heating lead designs typically mak
e use of water-cooled copper
plates
or tubes.
When
coil voltages are low (___800 V),
a low-inductance structure known
Excessivei
nductance
ltipiace
Design,
Elements of Induction
Control, and Applications
Design
and
239
Fabrication
(a)
(b)
Fig. 8.66. Semiflexible coaxial c
able
used to transmit power between
medium- or low-frequency power supp
lies and heat stations: (a) cross
section of coaxial cable and (b) c
able "broken out" for assembly (source:
American
Induction Heating Cor
p.)
----------------------- Page 236---------------------240
Heating:
Elements of Induction
Design, Control, and Applications
third
type
of
coaxial
increase
energy efficiency. At
other
times,
the
high
heating
rates
ch
ard
ree
for
acteristic
processing
of induction
are
of nonconductors.
neede
Th
broad
methods
of accomplishing
such objectives are described in this chapter. They make use of devices know
n as flux concentrators, shields, and susceptors.
Flux
concentrators
an
d
shields
are used
to modify
the
fiel
d of
magnetic induction (thereby shaping
the heating pattern)
or to prevent a
uxiliary equipment or certain portions
of a workpiece from being heated, respectively. Susceptors are materials
which are readily heated
by induction
and
which
subsequently
are used
to heat electrically nonconductive
materi
als
through
radiation
or conduction
heat-transfer
processes.
FLUX CONCENTRATORS
eld,
When placed in
magnetic materials tend
said to
e.g.,
hibit
an induction fi
to gather the
are
other
hand,
nonmagnetic materials
(
copper,
aluminum,
etc.) do
not ex
lative
The
to
ability,
that of
or the permeability
air, is of importance.
re
241
----------------------- Page 238---------------------242
n Heating:
flux
set up
and thus
field
Design,
Elements of
Inductio
Control, and Applications
t
heating
pattern.
The
means
by whic
h
this is accomplished is illustrated
in
Fig. 9.1. Here, it can be seen that a flux
concentrator in the form of a permeable iron
core causes
distortion of th
e
flux field surrounding the induction
coil. The permeable material presents an easie
r path
for
the flux lines; t
hus,
they concentrate in the permeable material.
By
concentrating
the
field
and
providing a better path,
stray flux can
be used to advantage. Because the voltage generated in an induction heated workpiec
e is proportional to AO/At,
or
the time rate
of change of the number
of lines of flux passing through the
part,
leads
larger
a greater number
of flux lines
to
a higher voltage and therefore
eddy currents in the workpiece.
Materials
for
Flux
Concentrators
Materials
for
flux concentrators
are
of two
basic
types:
(1) packages
of
laminated silicon steel punchings used at fre
quencies below
10 kHz,
an
d (2)
Flux
field with
singl
e-turn coil
Flu
x field with
sing
le-turn coil
and per
meable core
of
effect
flux
Flux Concentrators,
ting
made
hea
Design,
Shields,
and
Suscepto
Fl
ux field
ar
ound
a
panc
ake coil
ar
ound
a
panc
ake coil
wi
th
a flux
conc
entrator
Fig. 9.3. Use of a flux concentra
tor
in the center of a
pancake
coil to
increase the amount of magnetic
flux at this point and thus
the over-
all
Shield
heating efficiency
Design
Applications
like
flux robbers
of
Shields
(Chapter
8),
Elements
Design,
of
Control,
shown in Fig.
9.5.
It is used
on
a forging-line induction
co
il to
prevent
the
fields of adjacent inductors
fro
m affecting each other.
The pla
te is fabricated
of nonmagnetic
stainless
steel.
Design of the
current path
involves splitting
of the
closed loop
and
provision
of a larger
circuit with
ann
ular
slots,
thus
increasing the
resistance and
decreasing the
respective current.
In this
way,
shield heating
is greatly minimized.
Shields may also be used where a high-pow
er-density field used for hardening might
change the metallurgical stru
cture of adjacent areas on a part.
For
example,
a copper
shield is often
used
to
protect
gear teeth
while a boss
is
being
tempered
(Fig.
9.6).
Sim
ilarly, in Fig.
9.7,
a collar is
used to
protect
the
shoulder
on
a shaft while the
part
is hardened.
Along
I-I
(a)
: - : : :-;.:.:
: :::::::::::::::::::::::::::::::::::::::: : : . l
(b)
(c)
The short pattern
in (a)
can be widened, as in (b), by increasing the number of concentrat
or laminations.An even wider concentrator pattern (c) provi
des deeper heating at the edges of the
part.
Fig. 9.4.
Effect of flux-co
ncentrator
design on induction
he
ating
patterns
(from M. G. Lozinski
i, Industrial Applications of Induction Heating, Pergamon
Press, Lo
ndon, 1969)
----------------------- Page 243---------------------Flux
s
4 7
Concentrators,
Shields,
and
Susceptor
2
9.8).
Coils
and
shields of this
Design,
Elements of Induction
Control, and Applications
/
\"-k Itj r , J /
Fig. 9.6. Shield used to protect the
hardened surface of a gear while
the shoulder on the gear is being tem
pered (from M. G. Lozinskii,Industrial Applications of Induction Heat
ing, Pergamon Press, London, 1969)
tion,
or radiation.
It is used
where
the workpiece
cannot
be heated
to
the
desired temperature directly by induction. Becau
se it is solely a source of heat
and
is not part
of the process
itself,
a susceptor must
exhibit certain properties:
1. It must be readily heated
ion to
the process temperature.
2.
It must be inert with regard
process.
3.
It must be
readily
formable
able.
by
induct
to
or
the
machin
Shields,
and
Su
249
I
Heating without
a shield
Heating with a sh
ield
(a)
(
b)
Fig. 9.7.
Shield used to
prevent
heating of a shoulder on a shaft while
the remainder of the shaft surf
ace is being hardened (from M. G. Lozinskii, Industrial Applications
of Induction
Heating, Pergamon Press,
London,
1969)
used to
s
Fig. 9.8.
Split shields
reduce stray magnetic flux at the
end
of a
large
induction
coil;
laminations
on the vessel wall
act as flux
diverters
(source: Ameri
can
Induction
Heating Corp.)
----------------------- Page 246---------------------250
duction
Heating:
nd Applications
Elements of
Design,
Control,
In
a
Flux diverter
(runsfull length
Stainlessstee
lvessel
of v(
Split
(onlyat
~
endof
vessel)
~'
Fig. 9.9.
minations used to divert
field and
heating
within
a
el
High-permeability
la
the magnetic flux
thus
prevent stray
stainless steel vess
~ / ~
/ / / _ / ~ , RFIgasket
~
I
(a)
7
~
'
RFIga
sketon
I
bar
emetal
(b)
urface
Fig.9.10. Designof shields for
RF applicationsto prevent radiofrequency interference(RFI).Joints o
r seamsthat interlock (a) are
preferableto lapjoints (b)
----------------------- Page 247---------------------Flux
Concentrators,
Shields,
and
Susceptors
251
Typical
Applications
of Susceptors
As mentioned above,
susceptors may tr
ansfer the heat generated in them
to
the workpiece by processes such as condu
ction and radiation.
When this
heat transfer occurs by conduction, the suscepto
r and the workpiece may both
form a part
of the final product.
For
example, when steel tanks
are coated
with glass, the body of the vessel is heated
by induction. This in turn passes
its heat to the glass flit, which then flows
to provide the final glass coating.
Fig. 9.11. Range of
sizes and shapes
of
graphite
susceptors used in
induction heating applications (source
: GTE Products Corp.)
----------------------- Page 248---------------------2 5 2
tion
Heating:
pplications
Elements
Design,
Control,
of Induc
and
A
Induction
coil
Ceramic
pipe
oo
ooooo
/
I
I
I
Fluid
I
flow
Susceptor
I
I
I
0
0
application
ing
through
induction,
heat
from
the
suscaptors
In chemical processing,
conductiv
e piping
can be used
as a susc
eptor to
transfer heat directly to the process
fluid.
Generally these are low-frequency
systems in which the pipe is heated with line-fre
quency coils wrapped in a lowtemperature insulation. Air cooling may be suff
icient for the inductor in these
cases. In some instances, it is necessary to h
eat fluids passing through pipes
of nonconducting materials such as glass or c
eramics. A
susceptor of
suitable
material,
coated to prevent interaction w
ith the process,
may be susp
ended
in the fluid path
(Fig. 9.12). This in
turn is heated by an inductor on the outside of the pipe, transferring its heat to the
process material by conduction.
Susceptors need not have high resistivity if t
hey meet the other requirements
of the process. Accordingly, aluminum foil is t
he basic susceptor material in
packaging where it is used to transfer its heat
to a plastic coating such as polyethylene for making
seals.
Although the susceptors discussed above ess
entially transfer heat by direct
conduction to
the workpiece,
som
e applications use radiation
to
provide
a
noncontact method of heating for special proces
ses. In one instance, high temperatures are used in the continuous production
of carbon fibers. The material
itself cannot be heated
directly by i
nduction
due to its small diameter.
The
filament is passed
through
a graph
ite tube,
which is induction heated.
The
filament then,
in effect, is passing t
hrough
a high-temperature muffle,
and
is heated by radiation
from the inter
ior walls of the tube.
A
final application involves the manufact
ure of optical fibers from quartz
using a zirconia susceptor.
The dep
endence of the resistivity of zirconia on
temperature is such that it cannot be induction he
ated efficiently below 870 C
(1600
F).
Hence, it is radiation heate
d to this temperature by
an
auxiliary
graphite susceptor,
after
which it
is heated
directly using a radio-frequenc
y
(3-MHz)
induction power
supply.
----------------------- Page 249---------------------Elements of Induction Heating
Copyright 198
8 ASM International
Stanley Zinn, Lee Semiatin, p 253-280
All rights reserved.
DOI: 10.1361/eoih1988p253
www.a
sminternational.org
Chapter 10
Materials
Because
of
control,
induction
e of
ocess
can
ps
its speed
heating
and
is
eas
a pr
be
It
ste
ng.
of
-
Handling
seen the
large number
mated heating/handling/control
systems by induction equipment manufacturers. Power supplies, coil design,
and controls for these systems have been
covered in previous chapters. This c
hapter deals with materials handling and
automation. Basic considerations such
as generic system designs, fixture materials, and special electrical problem
s to be avoided are summarized first. This
discussion is followed by a descript
ion of typical materials-handling concepts
and illustrations
of specific appli
cations.
BASIC CONSIDERATIONSIN MATERIALSHANDLING
*
Part Movement Through Induction Coil
kpiece
rial
coil
and wor
of mate
asy to
parts
ancake,
Sim-
handling.
For
example,
it is e
visualize
continuous
motion
of
through, into,
or under
or channel coils (Fig.
solenoid, p
10.1).
from the
coaxial leads,
power
and
supply,
accommod
are therefore
J. F. Libsch, L
253
----------------------- Page 250---------------------254
Elementsof InductionHeat
ing:Design,Control,andApplications
Channel-type
inductioncoil
Ladderconveyor
Part
Stationaryinductionc
oil
\
/
l
Phosphorbronzespnng
(a)
(c)
Support
Magazine
feed
Inductioncoil
~
i
~
Continuousq, nch~ ID'~I:Ia r t.. .
Pu/her
Q
(b)
of
the
matic
drives may
not be
consistent.
Frequently,
automatic handling involves
another important requirement,
namely the delivery of the part
in t
he correct position at the correct instant
in time. Among the delivery techniques are au
tomatic conveyors with ingenious pickups, magazine feeds, and rotary tab
les.
Tooling for a specific appli
cation
can
often
be
constructed
ab
out
a standard
unit
using
convention
al
movements such as:
Handling
Stationaryinductioncoil
i";
/
Inductioncoil
~ ~ ' t ~
I~---~i
Part
x
Part
'
~ _l~
~ n g ~
\ r~l.~/~r~fixture "X~t.~i.~1~i
Indexing
m Li
turntable
Holding
Liftingmechanism
(b)
(a)
RFelectrical ,~
contact
~Xr
~\
Double-endedslidingfixture
Split-ty~:ingedcoil \
v~(
~\
StationaryinductioncoilPa~
-
\ \
(c)
(a) Part movement
into a f
ixed coil. (b) Coil movement
over
parts on an indexing turntab
le. (c) Double-ended
sliding f'Lxture.
(d) Split-type hinged
coil.
Fig.10.2.Indexing arrangements fo
handling-fixture
design (from
H. U.Erston and J. F.Libsch, Lepel
Handling Fixtures
Automation
processes
of induction
usually
involves
heating
contin
uous
feeding of parts
into or through the indu
ction coil and auxiliary equipment.
Typically, this involves handling of individual p
ieces in some sort of fixture.
Because the electromagnetic field extends beyo
nd the coil, fixtures made of
electrically conducting materials (e.g.,
steel) may be heated also, leading to
a costly loss of energy. For this reason,
fixture materials such as aluminum,
which heats less readily and which is easy to co
ol, and nonconducting materials are frequently used.
Some typical
selections for these types of applications
are listed in Table
10.1.
In some induction heating applications,
such as end heating of bars,
parts
can be
held
in place
far from the
coil, thereby permitting
irons
and
steels
----------------------- Page 252---------------------256
Heating:
Design,
Elements of Induction
Control, and Applications
to be used
in fixturing.
On
the other h
and,
in operations
such as soldering
and
brazing,
bonding
of the fixture
to the workpiece
as
well
as the corrosive
and
cumulative effects of
fluxes
must be
considered.
Aluminum, titanium,
and
some
nonmetallic
material
s
have
been
found
useful
instances. In addition,
when the
precisely locate the components
in these
fixture must
Table
10.1. Structural materials
for inducti
on
heating fixtures (from H.
U. Erston
and J. F.
Libsch, Lepel Review, Vol
1, No.
16, p
1)
Material
racteristicsand comments
Cha
Nonmetals
Diamonite(a)
y hard,
dimensionally
Aluminum
oxide; ver
stable;
standard
and special shapes;
resists high temperatures
Epoxy Fibre
Coil-mounting
support
s; good electrically; also useful for
Glass FF91(b)
soft soldering to ab
out 230 C (450 F)
Transite II(c)
Work-table tops; heat
resistant;
avoid for coil supports
(electrically poor)
Mycalex,
Various grades; useful
for high-temperature
coil supports;
Supramica(d)
special shapes availa
ble
Silicone rubber
Molds accurately;
fle
xible; useful for soft soldering to 315 C
(RTV)(e)
Fired Lava(f)
fore firing; good
(600 F)
Easily machinable
be
heat resistance;
less
strength than
Diamon
ite
Nonmagnetic
Aluminum
ork tables;
Brass
Metals(g)
alloys
Fixture base plates,
useful
for soft soldering
(does not bond)
(free
Supporting
screws,
w
l
Handling
257
1, No.
10,
3.
----------------------- Page 254---------------------258
on
Heating:
Design,
Elements
Control,
of Inducti
and Applic
ations
Controlled
atmosphere
Ceramic tube
Induction
coil
chai m ~ , ~
, Air-operated
pushrods
./
,
II
I
Ceramic jig
with part
p~q
Out
~~
-- ~,r-o~era,(e,eva,or
In
valves
(b)
(a) Brazing of brass watchband
clips without flux in a forminggas atmosphere.
(b) Fixture
using an elevator-pushrod arrangement.
s
n
Handling
259
Pyrex tube
I
I_1
()
II
I / l l
i~
I I J L
I1
InductiOncoil
support tube
l
Platinum
(b)
Gas inl
et
crucible
Metal
~k~,~
/
Gas retainer
Gas retainer
Gas outlet
(a)
/ ~ "
Silver
J/~'
\
Induction coil
secondary
Insulation
pedestal
~ / , J / / ~ / / / ~ , /
Sttubing a i n Isteel ess
Copper tube
/
Glass tub
e
brazing
alloy
ion
I ~
e%
Induct
A
co
il
Gas inlet
\
Brazed joint
(d)
Nickel c
an
Steel
pedesta
l
U
\
Hydrogen
(c)
(a)
rming
chamber
Coil
and
fixture
fo
for an argon
atmo-
Fig. 10.4.
holding fixtures
Adaptations
of
for introduction o
atmospheres
containment
of controlled
(from
Anon.,
Lepel Review,
Vol
1,
No. 10,
1)
Design,
Elements of Induction
Control, and Applications
Handling
261
In
cases, the
over-all handli
ng
system must
be
flexible eno
ugh
for
heating of billets or bars
with greatly differ
ing transverse dimensions. In the
case of circular billets,
for
example
,
it is usually required that
o
ne unit be
capable of heating stock whose diameter vari
es by a factor of two to three.
At
the
same time,
it must be capable
of heating billets of various
lengths.
Feed
most
Mechanisms
s.
Semiautomatic and
fully automatic systems are also available. With semiaut
omatic feeds, bars or billets are
pushed
from
a manually loaded magazin
e,
for instance, by
a hy
draulic or
pneumatic cylinder. They are pushed end-to-end t
hrough the induction coils
/f
,f
(
(a)
(b)
I
I "~
o[~
) " ' I
) 4 L
b
xJ
(c)
I
L
of it
(c) vers
Elements of Induction
Design, Control, and Applications
/
l
/ ,
f
(a)
(bl
verse
e
billet
axis is parallel to the feed direction. With
a transverse walking-beam heater
(Fig.
10.7b), the material
feed is tra
nsverse to the
axis.
----------------------- Page 259---------------------Materials
Handling
263
S
(a)
J
(b)
~
~
(a) and
con
Design,
Feed-MechanismSelection Criteria
Each of the various feed mechanisms has advan
tages and disadvantages that
must be considered during system design. The
continuous systems offer the
following advantages:
The mechanical feed device is very simple
whether it is driven hydraulically
or by compressed air.
The rate at which workpieces leave the c
oil line can be easily changed by
regulating a timer.
The equipment is inexpensive.
On the other hand, continuous lines suffer from
the problem of billets sticking
together. Furthermore, heating along the axis
of the bar or billet may be nonuniform if its length is not a multiple of the a
ctive length of the inductor. Caution must also be taken when billets become
shorter, lines longer, and peak
temperatures higher; under these conditions, t
he tendency for line buckling
increases, and
consideration should be given
to
walking-beam
feed mechanisms which totally eliminate problems
of
buckling and sticking together of
parts.
Other
advantages
of the walking-beam met
hod
include reduced maintenance and wear of the coil refractory lining and i
ndividual support/guide rails.
However, it has two basic drawbacks. First, t
he inside diameter of the inductor
must be greater than that required by
other systems with the result that
the efficiency decreases. Secondly, the over-all
cost of the feed system is considerably greater because of its complexity
and because of the extra guides
needed along the transport
path.
One other design feature that must be consi
dered with regard to feed equipment
is related to the feed rolls, guide ra
ils, or
supports that may hold the
workpieces in place.
Feed rolls are used
for heating long bars. When guide
rails are used (such as for very short piec
es), either two or four are usually
required (Fig. 10.9), depending on the cross-s
ectional geometry of the material
being heated. These rails are usually constructed
of steel tubing which is water
cooled, although high-temperature
supera
lloy and
nonmetallic (refractory)
guides, which
are not water cooled,
are
also in wide use. The
number
of
guides should be kept to a minimum because th
ey tend to absorb part
of the
thermal energy developed in the system through
radiation,
conduction, and
convection, as well as energy due to induced eddy
currents if they are metallic.
Keeping the diameter of the guide rails as smal
l as possible helps in minimizing
such energy losses.
MATERIALS HANDLING IN
HEAT TREATMENT
INDUCTION
Handling
of materials
during induction
heat treatment,
be it hardening,
tempering, or another process, depends to a g
reat extent on part
shape. How----------------------- Page 261---------------------Materials
Handling
265
.
..:
. . . . . . . .
:......'...
.,..
R
J
: . ' . ' . . - ~ ' . .
. . . .
. .
b o o "
I
B I O
t
, . . . . . "
. .
.'.
. . .
:
.
. .
R ~
s
J
. t
"
- .
o .
, . ,
O o
, o
ii
. . . . .
,-:
. -
- - . . ~
II
G
G
S-Induction
G
coil.
R-Refractory insulation.
G-Guide rail.
Fig. 10.9
Cro
ss sections of common induction coil-guide rail
arrangements used in bar and
billet handling
(from C. Dipieri,
Electrowarme
Int. B,
Vol 38,
No.
1,
February,
1980,
p 22)
ever,
handling
be
major
can
two
those
broken
de-
devices
into
categories:
s i g n e d
for
parts
of
section,
for
discrete
parts
which
continuous
regular
and
cross
those
typically preclude
continuous
i
feeding.
Several typic
n-line
al handling
schemes
are discussed
next
and
illustrate
d
with
examples.
It
should
be
borne
in mind,
however, tha
t
the kinds
of equ
ipment
for induction
heat treat----------------------- Page 262---------------------266
Elements of Induction Heating
: Design, Control, and Applications
ment
are innumerable. New
fixtures
nstantly designed to
fit new and
unique applications.
Continuous
Heat
are
co
Treatment
reatment
lines.
Treating, Vol
14, No. 9,
198
Handling
267
Supportbase
Temperature
Inducti
on
k
oil
Skewedheadassembly
Skewed sensor
Mainframe
'~X
rollers
Adjustablechuc
heatingc
\
/
,,/
Adjustable
Outfeed
/
Infeed
conveyo
,
conveyor
'
- - F:uOt;~o/ai ~
Materialflow
H
RFcontrol
I~L~achine/
,
~ i
andfault
operating~
H20quench
finder
I
I
Part-presentfiberoptics
control
I (
Temperingsection
Hardeningsection
,~
I
/
CR
ers
Main
contactors
/
S
Tripl
TrrannSftra~ind
=][=7
/
Triplers~
D D D D ~ / "
Controlpulpit ~
180-c
ycle
qqqqq -- heatingstations
le0-cycle
~
I
temperingcoils
Coolingbed
180-cycle
heatingcoils
heatingstations
andexittable
Entrytable
Pipe enters from the right, is a
ustenitized, quenched, drained,
and tempered. Following temperin
g, the pipe is transferred to
cooling
beds for air cooling.
Fig. 10.11.
Schematic
illustra
tion
of equipment used for in-line
induction
through hardening and tempe
ring of pipe-mill products (from R. M.
Storey, Metal Progress, Vol
101,
No. 4, April, 1972,
p 95)
Continuous Heat Treatment of Line Pipe.
Probably the largest application of induction through hardening and tempering is for p
iping or tubular goods used for
oil wells and gas pipelines. In a typical inst
allation,
such as that at Lon
e Star
Steel* (Fig.
10. l 1), processing is conducte
d on a continuous line on which the
steel is austenitized, quenched, tempered, and
finally cooled to room temper-
Vol
Elements of
Induct
Design, Control, and Applications
r
Inductor
Stitcher
Tension leveli
ng line
first
bridle
-I
I
Floor level
Air
knives
Quench
Fig. 10.12.
Schematic illustrati
on
of a
transverse-flux induction heat
treatment
line
used for proces
sing of aluminum
alloy sheet
(from R.
Waggott,
et al., Metals Techno
logy, Vol
9, December,
1982, p 493)
ature
at successive stations.
system, pipes
are loaded
n
entry
In
onto
this
a
Materials Handling
269
stock is fed from a payoff reel through
a
stitcher, which allows continuous
processing
of consecutive
coils without
line shutdown.
The
sheet is then
guided through the inductor at a constant s
peed by a set of drive rolls.
The
inductor
is mounted
on wheels to
allow
automatic
alignment of the
sheet
within it. The drive rolls also provide fron
t and back
tension to help maintain sheet flatness. After being heated, the
sheet is quenched and then dried
by a set of air knives. Upon exiting the l
ine, the material may be coiled, fed
into a leveling line, or routed to a subseq
uent processing station for
coating
or some other operation. Because the gage may v
ary, and to account for small
variations in sheet speed, the line is also fi
tted with thickness and speed monitoring devices whose signals are fed into a c
ontroller which adjusts the inductor power to
maintain the
desired temperat
ure.
Heat Treatment of Discrete Parts
Parts which are irregularly shaped or which
are selectively heat treated usually cannot be processed on a continuous bas
is.
In these cases, special fixtures
or handling
techniques
are required.
S
ome
of the
most
common
devices
include special scanning and single-shot equipment
, indexing turntables, rotary
tables, and robots,
which are briefly
disc
ussed below.
Shaft Hardening. Single-shot and
equipment
is used widely
in
scanning
the
1973,p 59.
Design,
Elements
of Induction
Control, and Applicatio
ns
moves over the rotating part,
heating
it to the desired temperature. A guide
shoe on the inductor maintains the proper air
gap between the inductor and
the part to ensure uniform heating and to m
inimize distortion.
The rotating
center at the spline end automatically compens
ates for thermal expansion as
the shaft is heated by applying a fixed load. Af
ter being heated, the workpiece
is indexed to
a quenching
station
f
or the
actual hardening
operation.
The
fourth, and final, station is another quench w
hich removes any residual heat.
Following these operations, the shaft is unloa
ded by a walking beam
onto
a
conveyor which then transfers it to the temperi
ng unit, which may be a similar induction-based
unit or a gas furnace.
Fully automatic,
horizontal
shaft
hardening by
scanning methods
is
also
popular.
Some of these devices allow loadi
ng and
scan hardening of multiple workpieces without operator assistance.
T
his is made possible by careful
design of walking-beam feeding systems and parts
chucking in the heat treating equipment.
indexing Turntables.
A popular machine for
automated handling and heat treating of small parts
is the rotary indexing
turntable.
Parts are loaded into a
n
elevated hopper that
feeds the machine al
ong an inclined steel track. Various
fixtures can be designed to locate the parts
when they are dropped
onto
the
table as well as to hold them in place. This
is particularly important for maintenance of precise distances between the part an
d an induction coil or an ejector (which may be used to push the parts into
a quench tank) at various stages
Remote quench
T
\
Power supply
I
I
' , \
1
! IV
Power supply
/
L /
' , \
I
Input-output conveyor
Ro
bot
Robot
console
Fig. 10.13. Schematic
illustration
of an automated
heat treatment cycle
including two vertical induction
scanning units, a
quench station, and
a
part-handling robot
(from P.
J. Miller, Heat Treating, Vol 14, No. 5,
May, 1982,
p 40)
----------------------- Page 267---------------------Materials
Handling
271
is illustrated in Fig.
10.14.
The table is water cooled from beneath.
Th
e overhead induction coil is flared
outward at its lower edge to prevent excessiv
e heating and thus hardening of
the lower portion
of the projectile.
As the table carries the projectiles from
beneath the coil, they are tipped
into a tank which provides an agitated water q
uench. The agitation also causes
the parts to be transported
along a helica
l ramp toward a discharge opening
onto a second chute. Here, the projectiles are
dropped into a perforated barrel
revolving in a soluble oil. This likewise has
a helical partition which finally
elevates and drops the workpieces by gravity in
to a tray
for stress relief in a
batch
furnace.
Robots.
The development of flexible manufacturi
ng systems and automation
in general has come about
in large measur
e because of industrial robots.
In
induction heat treating,
robots
are now u
sed to transport,
load, and unload
parts as well as to perform unpleasant tasks
such as quenching.
The application of robots can be illustrat
ed with a heat treating process for
internal ring gears described
by Loth.t
Following a washing
stage, a robot
first loads the gear in an induction preheat
ing
stage. After being heated to
345 C (650 F), the part is transported b
y robot to the second, or final, heating/austenitizing station. At the completion o
f this heating cycle, it is automatically lowered into a quench tank.
Next
,
the gear is transferred by robot
to a two-stage washer to remove the quench oil f
rom the part prior to the tem-
pering
operation.
Again,
the robot
takes
the part to the tempering
station,
after which it removes it and places it on
to a conveyor leading to
a machining area.
The use of robots for part handling/manipul
ation is sure to increase as the
"vision" and tactile capabilities of such m
achines are developed more
fully.
*Anon., Lepel Review, Vol 1, No. 2, p 8.
tR. W. Loth, Production, Vol 89, No. 4, April,
1982,p 80.
----------------------- Page 268---------------------2 7 2
ction
Heating:
d
Applications
Elements of Indu
Design, Control, an
Ejected sh
ot to quench
~
Ejector
finclers
Stationary bench
Heating coil
I
\
i2:!
I
" ~ " "
. . . . . . . . . .
, , ' l ~ ~L''I
~,,
i
Sprocket drive
Wa
ter
in
Rotat
ing joint
Section A-A
Fig. 10.14.
Plan
and cross
-sectional views of a rotary table arrangement used in induction heat treat
ment of armor-piercing projectiles
(from
Anon., LepelReview,Vol
1, No. 2,
p
8)
----------------------- Page 269---------------------Materials
Handling
273
Induction
coil
can
contour.
Several concepts for carrying out multiple
soldering operations sequentially
or simultaneously are shown in Fig.
10.16 and
10.17. Figure
10.16 shows a
turntable with a conveyor-type coil used to join
parts on which solder and flux
have been previously placed. The components are m
oved continuously through
the coil at a previously determined speed i
n order to
bring the joint
area to
soldering temperature.
Alternatively,
the turntable
may
be
set up with
an
indexing fixture in cases for which the
ust be localized. With this type
ol
heat m
Lepel Review, V
Design,
Elements of Induction
Control,
and Applica
tions
Fig. 10.16. High-production
indu
ction
soldering fixture utilizing
a turntable and
conveyor-type
coil wh
ich allows continuous part movement;
the inset
shows an
indexing a
rrangment for applications where
localized heating
is required
(from
J. Libsch and P. CapolongooLepelReview,
Vol
1, No. 5, p 1)
of
10.17
shows
multiple-position
springloa
ded pins
/
Tube
Solder
Induction
ring
coil
lange
Fig. 10.17.
Multiple-position fixtu
re
for soldering of four assemblies
at once; pressure pads ensure proper
component positioning during
induction soldering;the sketch at bot
tom illustrates positionsof induction coil and solder ring (from J. Li
bschand P. Capolongo,tepel Review,
Vol 1, No. 5,
p 1)
MATERIALS
NDUCTION
HEATING
HANDLING
IN
OTHER
PROCESSES
is
process
are
the
ability
to
form
parts
with
conven
Design,
Elements
Control,
of
Inductio
and Applica
Steel spring
/
Transite
Split
Inconel
liner
Thermal
insulation
Induction
double-layer
coil
Gold
ring
and setting
for
rom
rings
by
induction methods
(f
J. Libsch and P. Capolongo, Lepel
Review, Vol
1, No. 5, p
1)
Handling
277
I
K
G
F
Weld
~,
S'r
conta~
o ing
station
A-uncoilersand flatteners.B-cut fl
angefeeder.C-web upsetter. D-flange prebender. E-welder,
one each side. F-cooling
zone. G-straighteners,longitudinal
and flange.H-cutting saw.
I-runout and takeaway. J-scarfing.
K-flange joint finder.
Fig. 10.19. Schematic illustration
of facility utilizing high-frequency
welding
for fabrication of structur
al members
(source: Thermatool)
hoists,
and
charging buckets that
required
for materials-handling pur-
are
Design,
Elements of Induction He
Control, and Applications
in
the bottom
first.
Metal
splashing due to materials being
dropped into a molten metal bath.
Because of this hazard,
very little
charging is done by hand
or
by operators in cranes directly over an induction
furnace. Use of a tilting bucket on
the end of a mobile crane is the preferre
d method. Typically, this involves
loading of scrap into a chute which lead
s down to
an opening in the
fur
nace. An alternative device is the drop-botto
m bucket, consisting of a heavy
shell with a lifting yoke at the top
a
nd petal-type or clamshell doors at the
bottom.
The
doors
are opened by the
crane operator
or by gravity when
the bucket
is placed
on the
furnace.
Explosions due to
water
or oil en
trapped in the
charge material
and
c
arried below the surface. Preheating of the
charge to a temperature between
260 and
315
C (500 and
600 F)
eliminates this problem.
To avoid these and other problems, conveyors
and special drying equipment
for scrap are being used increasingly in induct
ion furnace charging operations.
Conveyors may be of the vibrating type, the
fiat-stroke type, or the belt type.
Charge materials
can be
spread out uni
formly and
charged at a given, constant rate to prevent the
furnace from b
eing overfilled. Rotary barrel
driers
for preheating and drying of scrap prior
loading onto a conveyor are also
to
increasing
in
popularity.
ROBOT DESIGN
With
ion,
the
the
increase
in factory
automat
use
of robots
in induction
system.
The
the abi
variety of
Faber and G.
P. Welch, Industria
Vol 53, No. 7, July, 1986, p
24.
tG. F. Bobart,
Process Control,"
Heating Homestudy
etals Park,
All robots
use one
order
to handle parts
or
more
within
arms
i
a pre-
One-arm
robots
usually have
no
rotational
Robotsl"
Elements of Induction
Control, and Applications
Design,
Power supply
(50 kW,
10 kHz)
Position sequence
Open grippers
Close grippers.
Dwell. Raise.
Wrist
'
A'
Rotate wrist
'A' 90 Rotate arm 90
T
.....
Pick-and-pl
ace
try conveyor
\
f l m ' ~
f
~ /
Lower
~,'\
~
En
'
mecnan,sm
F
Wrist,A
, ~
/ /
Open grippers.
l J l
Raise.
"'~
I /
Quench
Rotate wrist 'A' 90
~
~
Rotate arm 90
counterclockwise.
tank
t
/
ert
O0ec'ce ;t?
Open grip
per at 45
to
eject part
t
chute
Lower to
repeat cycle
ding
r
three
and
G.
4)
cal
encoders,
resolvers,
tachometers,
and
potentiometers
to maintain
the
velocity and position of each axis and ther
eby to provide a feedback control
signal. In point-to-point servo systems, contr
ol is programmed by storing discrete points in the robot's memory, which are
then used subsequently to carry
out the desired sequence of motions. A hand-he
ld pendant with separate buttons for each axis of motion is normally us
ed to
"teach" the program to th
e
robot.
Continuous-path servo-controlled systems are
similar to point-to-point systems except that
more extensive data
storage is involved, usually in a mem-
11
Special Applications
Induction
Heating
of
cial
features
such
as:
industries.
RUBBER INDUSTRIES
adhesives.
by
being
oined
r
be j
unde
281
----------------------- Page 278---------------------282
Heating:
Design,
Elements of Induction
Control,
and Applicatio
ns
with
a steel
Lepel Corp.)
localized heating
conditions.
To
acco
mplish this,
a susceptor
(Chapter
9),
which becomes a part of the final assembly, is
often used. For example, insertion of a wire ring in a special cavity of t
he assembly permits the use of induction
for local heating of the
area to
be joined.
Toilet-tank floats have
been
made in this manner
(Fig.
11. I)
by
using a steel wire ring inserted where the
two
float halves join.
Placing the wire
ring in an induction field causes it to
heat rapidly.
This in turn melts the adjace
nt rims of the plastic hemispheres,
causing them to form a plastic-to-plastic bond.
In this technique, proper joint
design ensures that the metal ring is fully
encompassed by the plastic at the
completion of the operation, precluding subseq
uent rusting of the wire.
I
f it
is desired to
heat
the plastic more slowly
, a gap
can be left between the ends
of the metal ring.
In
a similar approach,
the applicati
on
of localized heat
to thermoformable plastics may be employed to create a mechani
cal bond. Typically, the tang
of a metal kitchen utensil
such as a
knife or
a fork
(Fig.
11.2) is heated to
the
flow temperature
of the plastic h
andle
to which
it is to be joined.
T
he
heated tang is then inserted in the predrilled
or premolded handle, melting the
adjacent material and
forming a strong mechan
ical bond on cooling. If holes
or ridges are provided on the tang,
greater mechanical
strength can be
o
btained through the ability of the plastic to fl
ow into these areas. Twisted wirehandle
brushes,
similar to
bottle
bru
shes,
are
assembled in this
manner
as
well.
The plastic is deformed on contact w
ith the heated wire,
causing it
to
match the ridges in the twisted wire handle.
At
other
does not
times,
remain
the
a
metal
part
susceptor
of the
fi
nal
assembly but is used solely as a means of supp
lying heat to a plastic preform
which is to
be
shaped.
As
an
example,
catheters
for
medical treatment
are
----------------------- Page 279----------------------
Special
Applications
of Induction
Heating
2
83
Fig. 11.2. Application of inducti
on heating for attaching
knife
and brush
handles
(source:
Lepel
Corp.)
formed of inert plastic tubing and must have
specific shapes at their ends so
that they can be coupled to intravenous or si
milar types of apparatus.
In t
hese
instances, a stainless steel forming die is fa
bricated with internal channels for
water cooling (Fig.
11.3). In operation,
the die is heated by an induction coil
on an automatic forming machine. When the die
is raised to the forming temperature of the plastic, the tubing is mechan
ically pressed against it. Thereby,
the tubing
assumes the shape of the die.
The induction power is turned
off
and the die water cooling system is activated
to cool the plastic and thus
set
it in its new
shape.
Because
these
dies
are
normally
rather
small,
m
ost
machines of this type heat
and
form
multiple parts
simultaneously.
In some instances, it is not possible to
insert a metal ring or preform
into
an assembly where the deformation is carried
out.
The technique described
above for forming of catheters can then be util
ized with a movable die. In this
case, the die is heated by induction. When
it is at proper
temperature,
it is
then moved through the coil and pressed into the
assembly to deform the plastic. Induction heating is preferred to resista
nce heating of the die because of
----------------------- Page 280---------------------284
Heating:
ations
Work
Design,
Elements of Induction
Control, and Applic
coil
OC~O0
0
Water-cooled
ie
It
I , / / [ / / / / / / / / / / ~
~,
t//11/1////1/~r
Water
cooling
Fig. 11.3.
Schematic illustratio
induction
heating
method used to
form
catheter ends on tubing
Unlike resistan
Induction coil
Die (up
positio
n)
0
0
0
0
0
0
Die (staking
position)
Plastic lensJ
support
tube
Applications
of Induction
Heating
2
85
Plastic
Coatings
with
no
bed
Epoxy layer
Induction coil
ing
of
Fig. 11.5.
tool handles
using
induction
heating
(source
: Lepel Corp.)
----------------------- Page 282---------------------2 8 6
on
Heating:
tions
ing line for
Design,
Elements
Control,
of
and
Inducti
Applica
imide
film
on
wire
(source:
Lep
el Corp.)
from a spray gun and is attracted to the posi
tively charged metal being coated.
The part is passed through an induction heating
coil of proper frequency with
a suitable power
density, which results
in heating
of the powder
and
excellent
flow characteristics.
In each instance, the thermal conductivity
of the coating plays an important role in the process.
Because heat is tra
nsferred to the powder by conduction from the metal surface, the extent of
heat transfer
from the substrate
to
the powder decreases as the powder thickness i
ncreases. Coating thickness is
therefore limited by the properties
of the plastic itself.
Similar techniques are employed in insulati
ng electrical conductors using
polyemide film or
tape. The
high-te
mperature resistance
of the polyem
ide
film, which is applied in the form of high-integr
ity tape heat sealed to the conductor, permits thinner insulation than was
previously possible.
In thi
s case,
because the material will not bond directly to
copper, one or both
sides
of the
tape are coated with a fluorocarbon resin to
provide a heat-sealable surface.
The over-all arrangement of equipment for conti
nuous processing of insulated
conductors
is shown
in
Fig.
11.6
and
11.7.
It consists
of
equipment
for
Dual-headwrapping
machineanddrive
port
Radiant
Induction
Air-blastdryer
heaters
heater
/ Detergentbath
~
Water,
I ~.
\
,,,.
quenc~
\
t'~
igVVh;eners
Wind~up
~
~
~
Wirebrush
Trans
stra
~
/'
~ , ~
Un~t~n~ng
the
ce:
of
Induction
Heating
287
radiant heaters
for final curing, if desired
. A 40-kW RF generator operating
at 450 kHz heats the wire conductor to
approximately 300 C (570
F) at a
speed of 5 m/min
(15 fpm). The infrared r
adiation pyrometer focused on the
Operations
When
coated
materials
have
exhausted
their useful
life, the base-metal
structure may still have considerable value and
can be salvaged. Printing rolls,
vibration
eliminators,
and doffer
disks
on
cotton machinery
are typical of
assemblies that can be usefully and economically
salvaged with induction heating. For example, Fig.
11.8 depicts a coil
that is used to heat
152-cm- (60-in.-)
diam printing rolls
for this process.
In practice, the part is placed in a wor
k coil (Fig. 11.9), and the heat
produced
solely on the surface
of the metal
breaks
the bond
at the interface
Fig. 11.8. Induction heating arrangem
ent used to strip 152-cm (60-in.)
printing roils (source:American Induc
tion Heating Corp.)
----------------------- Page 284---------------------288
Heating:
s
Elements of Induction
Design, Control, and Application
Steel
J
insert
I
I
Induction
coil
case
\~'[ r~
r~ll~ 1
Rubber...
~11~
I~11~
I,n,ng
~ / / ]
ripping
r ~
Applications
of Induction
Heati
289
Fig. 11.10.
Photograph
of
mu
ltiplace
induction coil used for adhesive
bonding of
rotors
to
shafts
(source: Lindberg
Cycle-Dyne,
Inc.)
system uses a single RF generator
operating
two
alternate remote tanks
and
bonds both
sides of the assembly in appr
oximately
12 s. A
similar ap
proach
is utilized in the automotive industry where
insulation panels are bonded to
body parts.
The induction coil is on flex
ible leads. The adhesive to be cured
is preplaced on the stamped metal panels.
The insulation is put in place, a
nd
tor-and-shaft
ing operation
Fig. 11.11.
Photograph
of
assemblies being induction
heated during an
adhesive
(source: Lindberg CycleDyne,
Inc.)
ro
bond
Design,
Elements of Induction
Control, and Applications
During wel
After welding
Fig.
11.12. Illustration of
typ
of
Induction
Heating
291
flux
field is comparatively weak.
The coi
l must therefore be designed to be
as close to the joint as practical
while
maintaining
minimum
over-all coil
inductance.
INDUCTION
G
CAP
SEALING
AND
PACKAGIN
Design,
Elements of Induction
Control, and Applications
---Special Applications
of
Induction
Heating
293
Screwcap
Barriercap
Shoulder
Barriercap
Shoulder
dy
S e a m
Body
~
Fig. 11.15. Constructionof toothpaste
tubes that are assembled using
high-frequency induction heating (sou
rce:SAESA/GoodwayTools Corp.)
ductor materials,
nd vacuum tubes
e
products
which
technique.
cations
are
described
next.
this heating
other appli-
Zone
Refining
of
Semiconductors
Design,
Elements of
Control,
and
Induction
Applicatio
ns
coil further refine the product.
peration,
a multiturn coil, with
ons
counterwound to provide repetitive narrow
In o
secti
zones
(Fig.
same
in
11.17a),
produces
the
but
of refining
of Semiconductor
Single
Cryst
Seal
area
Aluminum/polyethylene
thylene
lap joint
to aluminum/polye
Fig. 11.16.
Bonding of aluminum/p
olyethylenejoints (such as for tooth-
uency
Applications
of Induction
Heating
295
desired electrical characteristics.
Th
e material is brought to its melting temperature, and a seed crystal of the proper
orientation is inserted into the melt,
rotated,
and
slowly withdrawn.
The
molten element solidifying on the end of
the seed crystal continues the
format
ion
of the single crystal.
Temperatur
e,
speed
of seed withdrawal,
and rotati
on
of the crucible are all critical to
the
process
and
control
both
the
diamet
er
of
the crystal
and the
dispersion
of
impurities. The process is temperature controll
ed on a programmed basis and
is performed in either an atmosphere or a v
acuum.
An infrared temperature
monitor
rol
the
or a sapphire
system is used
rod
to
thermocouple
sense and
cont
temperature.
Germanium crystals can also
be grown by
the zone-leveling method, which
employs essentially the same equipment as that
used in the germanium zonerefining method, with a single, oriented, impu
re seed added to one end of the
Multi
turn
inductio
n
coils
Molten
ries)
zone
Protective
Quartztube
atmosphere
(in se
~
/
oooo/
7.,/_.///.~.
00/00
,J~
~
Molten
/
Direction
of
~Y/'/////.~/
~- movement
of
I 0 0 0 0
/
boat
'
Carbon boat
Purezone
Impure
end
zone
Germanium
efining
Rotating
pulling
rod,
Silicon
up
rod
- -
Tube
Protective
Seed
atmosphere
o
o
Crystal
o
(~
o
Coil
I1!
Melt
zone
o
o
~
Molten zone
Thermocouple
with high
Multiturn coi
o
o
l
t ' ,
IIIo
Silicon
surface
Protective
tension
refining
crystal
atmosphere
and
Radiation
growing
pyrometer
Crystal
pulling
Fig. 11.17.
induction heating tec
hniques used in
processing of semiconductors (from J.
Davies and P.
Simpson, Induction Heating Hand.
book, McGraw-Hill,
Ltd., London,
1979)
----------------------- Page 292---------------------296
Elements of Induction Heat
ing: Design, Control, and Applications
graphite boat.
The rest of the boat contains
purified germanium; as the boat
is pulled through
an induction coil,
a sing
le crystal of the desired purity is
formed.
The
float-zone refining technique
for si
licon, also
called the Czochralski
crystal growing method, is another common techniq
Deposition
direction was the horizontal reactor (Fig. 11.18b). In this system, a graphite
susceptor which typically measures
approximately
10.2 by 76.2 by
1.3 cm (4 by
30 by 0.5 in.) is used. The major
design considerations are
as follows:
The frequency (450 kHz)
of the power
supply is chosen on the basis of the
thickness of the susceptor for most effecti
ve heating. To prevent field cancellation, the susceptor thickness must be
at least three times the reference
depth. It is desirable to keep this thic
kness to a minimum consistent with
efficient heating in order to minimize the
cooling time following processing. However,
some thickness greater than
the reference depth is required
to
minimize thermal
gradients in the su
bstrate
(wafer).
Power
requirements
are not determine
d by the
mass
of the susceptor as
much
as by radiation losses from its f
ree surface. At 1350 C (2460
F),
this radiation loss is 40 W / c m 2 (250
W/in. a) for a total loss of approximately 69 kW
for a susceptor of the abo
ve dimensions. An additional
10%
allowance
for loss to the hydrogen gas
must
also be made.
----------------------- Page 293---------------------Special
Applications
Heating
of
Induction
297
f \
o l d '
= ~ o
iz
II 0
II 0
~ L . . ~ / 0
(a)
b
k
f
/~LO
o
(b)
o
|
o I
I I
o/I
0/
gl
l ll,',lr~\,',\
~u / o
p//Ultg\U\~l I~
(c)
I
(d)
Fig. 11.18.
Induction sy
stems for
epitaxial deposition and CVD coating of semiconductors (from S.
Berkman,V. S. Ban, and N. Goldsmith,
Hetereepitaxial Semiconductors
for Electronic Devices, G. W. Cullenand
C. C. Wang, eds., Springer-Verla
g, New York, 1978, p 264)
A
further increase in the number of w
afers that
c
an be processed at any
one time has been
achieved with
the
design of the barrel
or
drum
reactor
(Fig.
11.18c). Here, the wafers are mounte
d in pockets on the outer surface
of a cylindrical susceptor. The coil surrounds t
he susceptor, which is rotated
for uniformity. The susceptor is somewhat conical
to equalize gas flow across
----------------------- Page 294---------------------298
ing:
Production of
Silicon Solar
Cells
Applications
of
Induction
Heating
299
If this were not provided, the heated air w
ould vent through the molten solder, preventing an optimal peripheral
seal. At the completion of the soldering
operation,
the
vent
may
be use
d
to introduce
a protective
atmosph
ere
before it is sealed. The soldering of the perip
hery of a semiconductor flat pack
can also be
done using induction heating.
Because the
area
to be hea
ted
is
greatly restricted, a metallic susceptor is hea
ted by the induction coil. The sus-
---300
ating:
Design,
Elements of Induction
Control, and Applications
Induction coil
He
Header
Solder
ring
D
U
U
Case
Vent
/
Fig. 11.20. Hermetic
of electronic case assemblies
(source: Lepel Corp.)
Manufacture
of Vacuum
solder
sealing
Tubes
Induction
heating
is also
widely
us
ed
in the manufacture
of TV
and
cathode-ray tubes.
It is utilized in outgass
ing and band
sealing (a shrink-fitting
process).
The metallic parts
of the tubes
are f
abricated in an
air environment, and
thus oxygen becomes entrapped in the metal. Th
e heat produced by the filaments in such tubes during operation would re
lease this oxygen, thereby oxidizing the metal
and
reducing
service l
ife. Outgassing during production is
thus required.
Typically, during outgassing,
each tube rests on a rolling cart
which proceeds through a long oven. The cart c
ontains its own vacuum pumping system which exhausts the air
in the tube
as it proceeds through the oven.
The cart
also carries a work coil which su
rrounds the electron-gun structure
in the tube. This coil is connected by
flexible leads and brushes to
a length
of buswork which in turn is connected to an ind
uction heating power supply.
The
metallic
parts
contained
in the t
ube
are induction
heated
to 850
C
(1560 F) as it travels through the oven, an
d the entrapped oxygen is driven
off. When the tube exits the oven, it is "ti
pped off" or sealed to maintain the
vacuum.
After the tube has been sealed, a slight
amount of oxygen still remains in
the tube envelope. A
small amount of mater
ial which rapidly oxidizes at high
temperature, usually barium,
is incorpor
ated as part
of the assembly in each
tube.
This is called a "getter."
In a sub
sequent operation, the getter is heated
----------------------- Page 297---------------------Special Applications
of
Induction
Heating
301
Elements of Induction
Design, Control, and Applications
leading to
the
Heat
cracking,
lated to
start or stop glass
much
as a stopcock controls
a pipe.
flow,
the
flow
from
Lens Blocking
When
optical lens blanks
have been rece
ived from a casting
system, they
must be ground to
specific contours depending
on their ultimate application.
This operation is performed by mounting the b
lank(s)
on a cast iron or steel
block which is used as a fixed base in grind
ing or polishing equipment. This
block is coated with pitch. The pitch is th
en heated to
a soft condition, utilizing an induction coil to heat the metal bas
e.
The blanks are locked in place
as the base cools and the pitch solidifies.
This heating
operation
generally
takes a matter of minutes as compared with the l
ong oven soaking times previously required.
Depending on the mass of th
e base,
power
supplies for this
application range from small RF generators to mu
ltiple blocking stations operated from
a central motor-generator
or so
lid-state supply.
Fiber-Optic Manufacture
Production of fiber-optic waveguides for te
lecommunications has become
a major technology. It is estimated that most
of the world's communications
will be carried
on optical fibers by the ye
ar 2000.
In its simplest form,
an optical wavegui
de is a
glass tube that has been
coated
on its inner or outer surface
with
an oxide layer that prevents
light
Applications
of
Induction
Heating
303
from passing through its walls. This tube is
then drawn into a fiber as small
as
125 #m
(5 mils) in diameter.
In
one process,
the glass preform,
appr
oximately 25 to
50 mm
(1 to 2 in.) in
diameter, is filled with a gaseous form of
germanium or
silicon. An
induction p
ower
supply operating at 2 to
5
MHz
is connected
to a work
coil that
is passed
at
a controlled
rate
over
the
preformed tube. A gas plasma is created whic
h oxidizes approximately 85%
of the germanium or silicon, evenly distributing
the coating over the inner surface of the preform and producing a light pipe
or light conductor. The treated
tube is then placed in a vertical chamber k
nown as a draw tower (Fig.
1
1.22),
where it is maintained in either an inert a
tmosphere or a vacuum.
Here,
the
glass is heated by radiation
from an
induction heated susceptor to a temperature at which it becomes electrically condu
ctive (815
C,
or
1500 F)
.
The
susceptor is removed, and an RF generator oper
ating at 2 to 5 MHz then couples
its energy
directly
into
the
now
-conductive glass,
raising
it to t
he re-
Design,
Elements of
Induct
Control, and Appl
Reflow
C,
or
450
F).
This
causes the
tin
surface
coil
,,king
nd
ding
of
erature
n
Fig. 11.23.
Schematic illustratio
of an induction-based,tin-reflow sys-
Simpson,
tem
(from J. Davies
and P.
Induction Heating Handbook,
McGraw-Hill,
Ltd., London, 197
9)
----------------------- Page 301---------------------Special
Paint
Applications
of
Induction
Heating
305
Curing
supply
/
Controls
Inducti
oncoil ._.~1
I-~
(1of
5)
/
l
Fromcoatingarea
Design,
metal.
In extreme cases, the
coating
spall
s, or porosity, which weakens the
coating, is developed. By contrast, the inducti
on heating technique cures from
the inside out, eliminating volatile elements th
rough the uncured coating and
achieving a much
stronger bond
between c
oating and base material.
In a typical high-speed induction curing line,
the heating portion of the system
occupies approximately 3 m (10 ft) of l
ine length. Material moves at a
maximum speed of approximately
180 m/mi
n
(600 fpm). Line speeds are limited only by the mechanical capabilities of the
of
Induction
Heating
307
Table
11.1. Typical
sizes an
d ratings
of
induction units
used for vessel
heating
(sou
rce: Cheltenham Induction
Heating,
Ltd.)
Vessel
Typical
working
Typical
vessel
heater
capacity
temperature
rating,
diamete
Nominal
r
in.
L
F
gal(a)
kW
5
300
570
300
570
10
24
30
40
54
60
72
78
84
90
96
102
300
300
300
300
300
300
300
300
300
300
300
300
570
225
570
450
570
1,150
570
2,300
570
3,500
570
5,000
570
7,000
570
8,500
570
10,000
570
12,000
570
14,000
570
(a)
glass
380
10
115
21
200
2
45
15
mm
25
530
20
50
610
30
100
50
250
100
500
150
750
200
1 1 0 0
300
1 5 0 0
375
1 8 0 0
450
2 2 0 0
550
2 6 0 0
600
3 0 0 0
675
Imperial
760
1000
1375
1525
1830
1980
2150
2300
2440
2590
gallons.
Solid sta
inless
steel vessels or vessels with
external jackets can
also be efficiently h
eated.
With induction heating of vessels, it is possi
ble to achieve input power densities much higher than those of other heating
systems. Inputs on the order
of 60 kW/m 2 (20,000 Btu/ft 2. h) are easily ob
tained. The only limitation is
the absorption capacity of the product or proce
ss. By comparison, the maximum operational power density of electrical-res
istance heaters is usually limited to approximately one-tenth that of induction
systems to reduce element
burnout. Another advantage of induction heating
is the fact that heat is generated uniformly within the vessel wall.
There are no
hot
spots which can
cause local overheating of the contents or deter
ioration of the tank.
In addition,
there
are
no
entry
and exit te
mperature
gradients
as are
normally
encountered in vessels heated by noninduction
methods.
Induction heating
also results in minimal thermal inertia because o
nly the vessel wall and contents are at elevated temperatures. This in tu
rn gives rapid control response
with
minimum temperature overshoot.
Because the vessel wall
is the heat
source in the induction heated system, the over-a
ll temperature gradient is significantly lower than with other methods. For e
xample, the typical maximum
temperature differential between the batch and the
vessel wall is 20 C (35 F)
while heating to temperature and 5 C (10 F
) during holding at the set point.
Coupled with the low thermal inertia, this all
of
Design,
Elements of Induction He
Control, and Applications
water-coolingcoil
~elthermal-insulation
et
Heaterterminalboxf
Inductionheating
coils
HeaterI
Fig. 11.25. Schematic
illustration
of vessel heating using low-frequency
induction (source: Cheltenham Indu
ction Heating, Ltd.)
APPLICATION OF INDUCTION HEATING
FOR VACUUM PROCESSES
The
Induction Heating
309
Design,
Elements of Induction
Control, and Applications
also
seal.
Solidification
Directional
solidification
popular
vacuum
melting
It
is frequently used
in
of superalloy blades
is another
process.
the
manufacture
for jet engines
(Fig.
11.27). In this technique,
the m
old
is supported
on
a pedestal whose
movement is closely controlled. The mold rests
vertically in the pouring position within an induction heating coil whose power
The creep
at the high
Melting
Applications
of
Induction
Heating
Design,
Elements
Control, and
of Induction
Applications
8
Water cooling
p
F////////A
V///////M
A
Bucking
()
plate
( k
(3
( ~
Levitation
coil
()
O
()
(
( )
Extra coaxial
~ - ~
turn
0
()
L
Typical parameters:
8 -- 30 to 45
d -- 9.5 to 19 mm (3/8to 3/4i
n.)
A -- 1.6 to 9.5 mm (1/18to % i
n.)
Coil frequency, -250 kHz
Coil current, to 650 A
rameters
Rapid
alloy preparation
Gas-metal reaction kinetic
studies
es
Solidification studies
Liquid slag and refractory
Melt
purification
and
reaction
studi
homogenization.
re
val
ri
315
----------------------- Page 311---------------------316
ing:Design,Control,and
Elementsof InductionHeat
Applications
Costs
10
I
I
8
Co
al
"
~
- ~ _
'
~
6
o~
0
2
0
I
I
1960
1970
1980
Year
Economics
317
tion heating, system efficiencies of 55 to
8
5/o are typical. For gas furnaces,
in which heat losses through doors, walls, etc.
are common, typical efficiencies
are 15 to 25%; with special insulation methods,
which, of course, increase the
furnace cost, it is reported that these efficie
ncies can be increased to perhaps
40 to 50%.
In any case, it is obvious that th
e higher efficiencies of induction
units can often offset the high cost of ele
ctricity.
Besides the energy used during the actual pro
cessing of material, the energy
required during idle periods should also be t
aken into account.
With induction systems, start-up is instantaneous.
In
addition, standby
power (needed
during
short delays in production)
is rat
her small, amounting to much
less
than
1 kVA for line-frequency and solid-state
equipment. For RF tube-type
power
supplies,
filament
power
is generall
y
shut off when
delays
exceed
30 min.
In comparison with induction units,
furnaces must be idled at fairly
high temperatures even when not in use during
off shifts. Thus, considerable
energy is still used during these periods.
The
effects of utilization level on
energy costs for several means of heating pri
or to
forging are illustrated in
Fig. 12.2. In this plot, data are given for a
typical motor-generator induction
system as well as for a direct-resistance he
ating method.
Not shown is the
trend for solid-state induction power supplies,
which lie between "whole-piece"
induction heaters
and direct-resistance units.
Ease of
Automation
and
mai
Elements of
Design
Applications
140
I
I
120
100
Lypic
al
icity
.
t O
8 0 - -
0
t..)
0")
t t~
-1-
6 0 - f
urnace
:ienc
y
18%)
pical
induction
4 0 - -
r-end
heater
Whole-piece
J
induction
2 0 - heater
ct
resistance
heater
O
~
0
20
60
80
Operating
reduced
various
40
output
output
100
Fig. 12.2.
on heating
capacity,
Effect
efficiency
of
of
and
Scale and
particular
an
ysis because a
Scrap
Losses
scrap
economic
large part
losses are of
importance in
anal-
Design,
Elements of Induction
Control, and Applications
parts
are usually less costly than
tical furnace-heated or furnace heat
treated parts.
TYPICAL
COST
for
iden
COMPARISONS
The
above
(and
other
pertinent,
ap
plication-dependent)
factors
can be
employed to estimate the economic feasibility of
candidate induction heating
processes.
Several typical examples are given
below to illustrate the methodology.
Heating of
Steel Billets Prior to Forging
Cost analyses for the induction heating of
steel billets prior to forging have
been
quoted
many
times
in the literat
ure.
Invariably,
it is concluded that
induction heating for steel forging is very a
ttractive. Examples of such analyses are given in Tables
12.1 and
12.2.
The first example (Table
12.1) is for
an induction system operating at 52/o
efficiency and
a gas-fired furnace at
1
7.570 efficiency. Neglecting the capital investment, it can be seen that
the on
ly item for which induction poses a
greater expense is energy. With the more rapid in
crease in gas prices since 1980
(the most recent year for which costs are
estimated in the table),
the differential has decreased somewhat. It can also
be noted
that
substantial savings
in labor and in scrap and
scale losses ar
e realized through the use of induction, leading to lower over-all operating costs
. Such lower costs can aid in the
amortization of the induction equipment in an
equal or shorter period of time
in a high-production
shop.
1977 cost(a)
1980 cost(b)
Induction
Energy . . . . . . . . . . . .
. . . . . . . $8.34
$12.70
Production labor . . . . . . .
. . .
0.93
1.25
Maintenance labor
. .
. . . . . . 0.33
0.44
Scale
loss
. . . . . . . .
. . . . . . . . 1.75
2.33
Scrap loss . . . . . . . . . .
. . . . . . 1.75
2.33
TOTAL . . . . . . . . . . . . .
. . . . . $13.10
$19.05
Natural
Gas
Energy . . . . . . . . . . . . .
. . . . . . $5.93
$9.20
Production labor . . . . . . .
. . .
1.87
2.49
Maintenance labor
. .
. . . . . . 0.67
0.89
Scale loss
. . . . . . . .
. . . . . . . . 7.00
9.34
Scrap loss . . . . . . . . . .
. . . . . . 7.00
9.34
TOTAL . . . . . . . . . . . . .
. . . . . $22.47
$31.26
(a) Cost per ton of product i
n 1977dollars. (b) Cost per ton
of product in
1980dollars.
num
billets
prior
to extrusion using
induction
and
gas
furnaces
were
estimated.
The analysis showed the cost of the
former method to be about twice
that for the latter when the cost elements
Treating
of
Steel
Stutz,Induction
Steel, American So
1986.
322
Heating:
Design,
Elements of Induction
Control, and Applications
Table
12.2. Economic comparison between
induction
and
gas-fired furnace
heating of forging
billets(a)
(
from J. Skelton, private communication, Battelle Columbus Division,
Col
umbus, OH, September,
1984)
Induction
Item
installation
Gas-fired
furnace
Installation cost
$600,000
$200,000
Heating efficiency
60%
15%
Annual energy cost
$720,000
$540,000
Scale loss
1/2%
2%
Scrap loss
1/4%
1%
Annual scrap and scale loss cost
$150,000
$600,000
Labor requirement
1 operator;
1/4
2 operators;
1/2
maintenance
maintenance
Annual labor cost
$60,000
$120,000
Total annual operating cost
$930,000
$1,230,000
(a) Hot forging of steel. Annual
thro
ughput,
30,000 tons.
Annual
hours of
operation, 4000. Value of raw material, $500
/ton. Value of product scrap, $t000/
ton.
Labor
cost, $12/h.
Energy cost: e
lectricity, $0.06/kW.h; gas, $4/MBtu.
For
surface-hardening
induction appears to
applications,
hold
a consider-
able
cost
advantage
over
other
establ
ished
methods.
These
other
methods
include salt-bath nitriding,
gas nitriding
,
and
carburizing. Using pricing data
from
commercial heat treaters,
it has
been
estimated that
the
over-all
cost
s
of the various processes are in the ratio
of 0.11 to 1.75 to
8 to 2.5 for induction,
salt-bath
nitriding,
gas
nitridin
g,
and
carburizing
methods
of
cas
e
hardening.*
Thus,
in applications in whic
h geometry and production volume
allow the use of induction, it is the prefe
rred surface-hardening method
from
a
cost standpoint.
Several recent technologies have
em
erged that
could
compete with induction surface hardening on a cost basis.
These are laser and electron-beam surface
hardening.
Generally
these
proc
esses
are
employed
to obtain
rathe
r
shallow case-hardened depths (0.05 cm or 0.02
in.,
or less). In these instances,
and
ion
for
which
induct
design,
kW.
per
Arc
Power,
Thickness,
m /h
Arc
30
or
amps
ft
Process(b)
kW
cm
(in.)
(ft/h)
volts
100
F C A W
325
. . . . . 0.32
9.1
60
28
4.6
(0.125)
(200)
H F R W
. . . . 0.32
275(c)
4,025
. .
. . . .
2.1
(0.125)
(13,200)
F C A W
475
. . . . . 0.64
13.3
40
28
10.6
(0.25)
(125)
S A W
900
. . . . . . 0.64
29.7
40
33
22.8
(0.25)
(130)
. .
H F R W
. . . . 0.64
555(d)
3,600
. . . .
4.7
(0.25)
(11,820)
S A W
1100
. . . . . . 1.27
37.4
25
34
41.6
(0.50)
(90)
. .
H F R W
. . . . 1.27
1100(e)
2,560
(0.50)
(8,400)
. . . .
13.2
(a) Data
for
WeldingHandbook, 7th
arc
welding
are fro
Edition,
Vol
2,
W. H. Kearns, ed., American Welding Socie
ty, Miami,
1978, pp 177, 179, and 210
.
Data for high-frequency welding are fro
m Thermatool Corp. (b) FCAW
= fl
uxcored arc welding. HFRW
= high-f
requency resistance welding (similar to high=
r
requirement
for 160-kW welder output
capacity. (d) Input-power requirement
for
300-kW welder output capacity. (e) Inpu
t-power requirement
for 600-kW welder
output
capacity.
Tube Welding
The use of high-frequency induction and resist
ance heating for tube welding
also appears very attractive from a cost vi
ewpoint. Not
only is the cos
t per
unit of product considerably less with these tech
niques than with submergedarc welding (SAW) and
fluxed-cored
arc welding (FCAW),
but produc
tion
rates are more than
an order of magni
tude greater (Table
12.3), thus g
iving
rise to
substantially lower labor costs.*
*H.
High
N. Udall,
Frequency
"Energy
Saving Through
Electric
Resistance
W
elding,"
unpublished
amford, CT,
paper,
1984.
Thermatool
Corp.,
St