Induction heating is a process that uses electromagnetic induction to heat conductive materials, such as metals and semiconductors. The heating is caused by eddy currents, which are induced in the material by a rapidly changing magnetic field. The frequency of the magnetic field is typically in the range of 10 kHz to 1 MHz, and the power level can be adjusted to control the rate of heating. The temperatures are as low as 100 ºC (212 °F) and as high as °C ( °F) .It can be used in brief heating processes that are on for less than half a second and in heating processes that are on for months.
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The Benefits of Induction heating over other heating methods, such as:
* Efficient, with up to 98% of the energy being converted to heat.
* Fast, with the material typically reaching the desired temperature in seconds.
* Precise, with the heating area being limited to the area within the induction coil.
* Safe, with no emissions or fumes or flame
Extended Life of Fixturing due to precise heating
Induction heating is a versatile and efficient heating method that is used in a wide variety of applications. It is a safe, precise, efficient, and clean process that offers several advantages over other heating methods.
Induction heating is used in domestic and commercial cooking, and in many applications, such as melting, heat treating, preheating for welding, brazing, soldering, curing, sealing, shrink fitting in industry, and in research and development.
Induction heating is used in a wide variety of applications, including:
* Metalworking, such as hardening, annealing, and welding
* Plastics processing, such as melting and forming.
* Food processing, such as cooking and pasteurization.
* Medical applications, such as surgical sterilization and cancer treatment
Difference between Induction Heating and Resistance Heating
Heating is a process of increasing the temperature of a body to an acceptable level by using thermal energy. The mechanism involved in heating is generally referred to as a heating system.
When the process of heating is performed by using the electric current, i.e. the electric current is converted into heat energy by employing a suitable mechanism called the electric heating. The principle behind the electric heating is the heating effect of electric current which states that when an electric current flows through a conducting medium, the medium resists the flow of this current which results in the rise in temperature of the medium, i.e. the heating of the medium.
Today, different methods of electric heating are available like resistance heating, induction heating, arc heating, dielectric heating, etc.
Basis of Difference
Induction Heating
Resistance Heating
Definition
The type of electric heating in which object is heated by the process of electromagnetic induction is called induction heating.
The type of electric heating in which object is heated due to only the resistance of the material of the object is called resistance heating.
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Principle of heating
The electromagnetic induction is the principle behind the induction heating.
The power loss in resistance (I2R loss) is principle used in the resistance heating.
Types
There are two types of induction heating namely, direct-induction heating and indirect induction heating.
There are two types of resistance heating namely, direct resistance heating and indirect resistance heating.
Current carrying part
In case of induction heating, the electric current flows through a coil of an electromagnet of the induction heater.
In resistance heating, the electric current flows through a wire of high resistance to produce heat.
Heating part
In induction heating, the heat is directly produced in the object to be heated by the electromagnetic induction.
In resistance heating, the heat is produced by a resistance wire and then transferred to the object to be heated.
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There are several standards governing the inspection of carbon steel assets, structures, and
Much has been written, discussed and debated about the values of the process of induction heat treatment. Induction heat treatment is a now a mature process technique that offers clean work, high-speed production, easily automated process and repeatable metallurgical results.
The process works on the simple principle that when an electrical current is passed through a conductor, an electro-magnetic field is created around the conductor. The conductor is generally (not in all cases) a coiled copper conductor through which a high-frequency magnetic field is induced to flow through the coil. This sets up a magnetic field around the coil and within the coil. If a steel bar is inserted into the coil, the magnetic flux that is generated will create eddy currents within the surface of the steel bar, which creates heat within the immediate surface of the inserted bar within the conductance coil.
The depth of the heated and hardened surface will be dependent on the carbon content of the steel bar, induction frequency, induction power, residence time within the coil and quench medium.
The steels that can be used for an induction heat-treatment procedure will generally contain approximately 0.3-0.5% carbon. Care needs to be taken with the higher carbon grades for the potential risk of cracking. Chromium can be added to the steel (generally 0.25-0.35%) to interact with the carbon content of the steel and produce surface chromium carbides.
It is at this point that the decision should be made if the system will quench with water or a poly-alkaline glycol mixture to reduce the risk of cracking. The induction coil can be designed to accommodate any geometric shape that will allow access to the contour to be heat treated and quenched accordingly.
The following will show some of the advantages and disadvantages of induction heat treatment.
Advantages
Disadvantages
Do not be under any illusion that the process is distortion-free. The degree of distortion that will occur will be dependent on the amount of prior working that has occurred to the product when machining. Distortion will occur.
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