Induction heating

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Induction heating is the process of heating an electrically conducting object (usually a metal) by electromagnetic
induction, through heat generated in the object by eddy currents (also called Foucault currents). An induction heater
consists of an electromagnet, and an electronic oscillator that passes a high-frequency alternating current (AC) through
the electromagnet. The rapidly alternating magnetic fieldpenetrates the object, generating electric currents inside the
conductor called eddy currents. The eddy currents flowing through the resistance of the material heat it by Joule heating.
In ferromagnetic (and ferrimagnetic) materials like iron, heat may also be generated by magnetic hysteresis losses.
Thefrequency of current used depends on the object size, material type, coupling (between the work coil and the object to
be heated) and the penetration depth.
An important feature of the induction heating process is that the heat is generated inside the object itself, instead of by an
external heat source via heat conduction. Thus objects can be very rapidly heated. In addition there need not be any
external contact, which can be important where contamination is an issue. Induction heating is used in many industrial
processes, such as heat treatment in metallurgy,Czochralski crystal growth and zone refining used in
the semiconductor industry, and to melt refractory metals which require very high temperatures. It is also used in induction
cooktops for heating containers of food; this is called induction cooking.
Contents [hide]
1 Applications
1.1 Induction furnace
1.2 Induction welding
1.3 Induction cooking
1.4 Induction brazing
1.5 Induction sealing
1.6 Heating to fit

Component
ofStirling
radioisotope
generator is
heated by
induction during
testing

1.7 Heat treatment

1.8 Plastic processing
2 Details
3 Core type furnace
4 References

Applications

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Induction heating allows the targeted heating of an applicable item for applications
including surface hardening, melting, brazing and soldering and heating to fit. Iron and
itsalloys respond best to induction heating, due to theirferromagnetic nature. Eddy
currents can, however, be generated in any conductor, and magnetic hysteresis can occur
in any magnetic material. Induction heating has been used to heat liquid conductors (such
as molten metals) and also gaseous conductors (such as a gas plasma - see Induction
plasma technology). Induction heating is often used to heat graphite crucibles (containing
other materials) and is used extensively in the semiconductor industry for the heating of
silicon and other semiconductors. Utility frequency(50/60 Hz) induction heating is used for
many lower cost industrial applications as inverters are not required.

Induction furnace

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Induction heating of 25 mm metal bar using 15 kW

at 450 kHz.

An induction furnace uses induction to heat metal to its melting point. Once molten, the
high-frequency magnetic field can also be used to stir the hot metal, which is useful in
ensuring thatalloying additions are fully mixed into the melt. Most induction furnaces consist of a tube of water-cooled copper rings surrounding
a container of refractory material. Induction furnaces are used in most modern foundries as a cleaner method of melting metals than
a reverberatory furnace or acupola. Sizes range from a kilogram of capacity to a hundred tonnes capacity. Induction furnaces often emit a highpitched whine or hum when they are running, depending on their operating frequency. Metals melted include iron and steel,copper, aluminium,
and precious metals. Because it is a clean and non-contact process it can be used in a vacuum or inert atmosphere. Vacuum furnaces make
use of induction heating for the production of specialty steels and other alloys that would oxidize if heated in the presence of air.

Induction welding

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Main article: Induction welding

A similar, smaller-scale process is used for induction welding. Plastics may also be welded by induction, if they
are either doped with ferromagnetic ceramics (where magnetic hysteresis of the particles provides the heat
required) or by metallic particles.
Seams of tubes can be welded this way. Currents induced in a tube run along the open seam and heat the
edges resulting in a temperature high enough for welding. At this point the seam edges are forced together
and the seam is welded. The RF current can also be conveyed to the tube by brushes, but the result is still
the same the current flows along the open seam, heating it.

Induction cooking

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Main article: Induction cooking

In induction cooking, an induction coil in the cook-top heats the iron base of cookware by cyclic magnetic
induction. Copper-bottomed pans, aluminium pans and other non-ferrous pans are generally unsuitable. The
heat induced in the base is transferred to the food via (metal surface) conduction. Benefits of induction
cookers include efficiency, safety (the induction cook-top is not heated itself) and speed. Both permanently
installed and portable induction cookers are available.

Induction brazing

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Main article: Induction brazing

Induction brazing is often used in higher production runs. It produces uniform results and is very repeatable.

Induction sealing

Melting silicon in crucible at

2,650 F (1,450 C)
forCzochralski crystal growth,
1956

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Main article: Induction sealing

Induction heating is used in cap sealing of containers in the food and pharmaceutical industries. A layer of aluminum foil is placed over the
bottle or jar opening and heating by induction to fuse it to the container. This provides a tamper-resistant seal, since altering the contents
requires breaking the foil.[1]

Heating to fit

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Induction heating is often used to heat an item causing it to expand prior to fitting or assembly. Bearings are routinely heated in this way
using utility frequency(50/60 Hz) and a laminated steel transformer type core passing through the centre of the bearing.

Heat treatment

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Induction heating is often used in the heat treatment of metal items. The most common applications are induction hardening of steel parts,
inductionsoldering/brazing as a means of joining metal components and induction annealingto selectively soften an area of a steel part.
Induction heating can produce high power densities which allow short interaction times to reach the required temperature. This gives tight
control of the heating pattern with the pattern following the applied magnetic field quite closely and allows reduced thermal distortion and
damage.
This ability can be used in hardening to produce parts with varying properties. The most common hardening process is to produce a localised
surface hardening of an area that needs wear-resistance, while retaining the toughness of the original structure as needed elsewhere. The
depth of induction hardened patterns can be controlled through choice of induction-frequency, power-density and interaction time.
Limits to the flexibility of the process arise from the need to produce dedicated inductors for many applications. This is quite expensive and
requires the marshalling of high current densities in small copper inductors, which can require specialized engineering and 'copper-fitting'.

Plastic processing

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Induction heating is used in plastic injection molding machines. Induction heating improves energy efficiency for injection and extrusion
processes. Heat is directly generated in the barrel of the machine, reducing warm-up time and energy consumption. The induction coil can be
placed outside thermal insulation, so it operates at low temperature and has a long life. The frequency used ranges from 30 kHz down to 5 kHz,
decreasing for thicker barrels. The reduction in cost of inverter equipment has made induction heating increasingly
popular.[citation needed]Induction heating can also be applied to molds, offering more even mold temperature and improved product quality.[2]

Details

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The basic setup is an AC power supply that provides electricity with low voltage but very high current and high frequency. The workpiece to
heat is placed inside an air coil driven by the power supply, usually in combination with a resonant tank capacitor to increase the reactive
power. The alternating magnetic field induceseddy currents in the workpiece.
Applications of frequency ranges
Frequency (kHz)
Workpiece type
530

Thick [clarification needed] materials

100400

Small [clarification needed] workpieces or shallow penetration

480

Microscopic pieces

Magnetic materials improve the induction heat process because of hysteresis. Materials with high permeability (100500) are easier to heat
with induction heating. Hysteresis heating occurs below the Curie temperature where materials retain their magnetic properties. High
permeability below the Curie temperature in the workpiece is useful. Temperature difference, mass, and specific heat influence the workpiece
heating.
The energy transfer of induction heating is affected by the distance between the coil and the workpiece. Energy losses occur through heat
conduction from workpiece to fixture, natural convection, and thermal radiation.
The induction coil is usually made of copper tubing and fluid cooled. Diameter, shape, and number of turns influence the efficiency and field
pattern.

Core type furnace

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The furnace consists of a circular hearth which contains the charge to be melted in the form of angular ring. The metal ring is large in diameter
and is magnetically interlinked with an electrical winding energized by an AC source. It is essentially a transformer where charge to be heated
forms a single turn short circuit secondary and is magnetically coupled to the primary by an iron core

References

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1. ^ Valery Rudnev Handbook of Induction HeatingCRC Press, 2003 ISBN 0824708482 page 92
2. ^ Dong-Hwi Sohn, Hyeju Eom and Keun Park, Application of high-frequency induction heating to high-quality injection molding, in Plastics
Engineering Annual Technical Conference Proceedings ANTEC 2010, Society of Plastics Engineers, 2010

Brown, George Harold, Cyril N. Hoyler, and Rudolph A. Bierwirth, Theory and application of radio-frequency heating. New York, D. Van
Nostrand Company, Inc., 1947. LCCN 47003544
Hartshorn, Leslie, Radio-frequency heating. London, G. Allen & Unwin, 1949. LCCN 50002705
Langton, L. L., Radio-frequency heating equipment, with particular reference to the theory and design of self-excited power oscillators.
London, Pitman, 1949. LCCN 50001900
Shields, John Potter, Abc's of radio-frequency heating. 1st ed., Indianapolis, H. W. Sams, 1969. LCCN 76098943
Sovie, Ronald J., and George R. Seikel, Radio-frequency induction heating of low-pressure plasmas. Washington, D.C. : National
Aeronautics and Space Administration ; Springfield, Va.: Clearinghouse for Federal Scientific and Technical Information, October 1967.
NASA technical note. D-4206; Prepared at Lewis Research Center.