What is Induction Melting Furnace?
India Powermelt Pvt.Ltd. (IPM Group) is a renowned company specializing in the use of electromagnetic induction for melting, heating, and welding applications across multiple industries. With a deep understanding of physics, electromagnetism, power electronics, and process control, we provide advanced induction heating equipment and solutions. Let’s explore the basics of induction and its advantages over other heating methods:
Introduction Melting
For many processes melting is the first step in producing a useful product induction melting is fast and efficient. By changing the geometry of the induction coil, induction melting furnaces can hold charges that range in size from the volume of a coffee mug to hundreds of tons of molten metal. Further, by adjusting frequency and power, IPM Group companies can process virtually all metals and materials including but not limited to: iron, steel and stainless steel alloys, copper and copper-based alloys, aluminum and silicon. Induction equipment is custom-designed for each application to ensure it is as efficient as possible.
A major advantage that is inherent with induction melting is inductive stirring. In an induction furnace, the metal charge material is melted or heated by current generated by an electromagnetic field. When the metal becomes molten, this field also causes the bath to move. This is called inductive stirring. This constant motion naturally mixes the bath producing a more homogeneous mix and assists with alloying. The amount of stirring is determined by the size of the furnace, the power put into the metal, the frequency of the electromagnetic field and the type/amount of metal in the furnace. The amount of inductive stirring in any given furnace can be manipulated for special applications if required.
Induction Vacuum Melting
Induction heating offers unique advantages for processing reactive metals and sensitive materials due to its ability to heat the workpiece without direct contact with the induction coil. The magnetic field generated by the coil can penetrate non-conductive barriers, allowing for heating in controlled environments, such as vacuum or inert atmospheres. This capability is particularly valuable for materials like titanium, aluminum, and specialty alloys, which may react adversely with oxygen or other contaminants at high temperatures
What is Induction Heating ?
The magnetic field generated by the coil induces voltage in a conductive workpiece when it is placed within the changing magnetic field. This phenomenon, known as Faraday’s Law, leads to the flow of electrons or current in the workpiece. The direction of the current in the workpiece is opposite to the current in the coil.
The Joule Heating Effect
As current flows through the workpiece, the resistance encountered by the electrons generates heat. This is known as the Joule Heating Effect. While materials with higher resistance produce more heat, even highly conductive materials like copper can be heated using induced current.
How Does Induction Heating Compare to Other Heating Methods?
There are several methods to heat an object without induction. Some of the more common industrial practices include gas furnaces, electric furnaces, and salt baths. These methods all rely on heat transfer to the product from the heat source (burner, heating element, liquid salt) through convection and radiation. Once the surface of the product is heated, the heat transfers through the product with thermal conduction.
Induction-heated products do not rely on convection and radiation for the delivery of heat to the product surface. Instead, heat is generated in the surface of the product by the flow of current. The heat from the product surface is then transferred through the product with thermal conduction. The depth to which heat is generated directly using the induced current depends on something called the electrical reference depth.
Electrical Reference Depth of High and Low Frequency
The electrical reference depth depends greatly on the frequency of the alternating current flowing through the workpiece. Higher frequency current will result in a shallower electrical reference depth, while lower frequency current will result in a deeper electrical reference depth. This depth also depends on the electrical and magnetic properties of the workpiece.
Indiapowermelt Group India companies take advantage of these physical and electrical phenomena to customize heating solutions for specific products and applications. The careful control of power, frequency, and coil geometry allows the Indiapowermelt Group India companies to design equipment with high levels of process control and reliability, regardless of the application.