137 Carlisle Street
Heat treatment Hardening of Lawnmover Blades
Purpose-built system for edge hardening of lawnmower bottom blades. Power is from 12Kw Ultratec RF induction heater.
Traditional Valve Type RF Induction Heater
Typical old valve technology type power unit for comparison with new compact Ultratec. Disadvantages of this technology are large footprint, high voltages, reliability and Health and Safety concerns.
Edge Hardening of Shear Blades
Edge hardening of shear blades using 40Kw Ultratec RF power unit in a fully automated system complete with hydraulic clamp quenching. Similar units have been used for lopper blades, plane blades, pruner blades, wood chisels, etc. Ultratec units are available as part of a Turnkey system or as a standalone unit.
Induction Bending for Fork Lifts
Bending for production of Fork Lift Forks. Heating large sections for the production of fork lift forks.
Shear Blade Hardening System
Fully automated shear blade hardening system, complete with hydraulic clamp quench and magazine load. Power is 40Kw Ultratec RF induction heater.
Frequently Asked Questions About Induction Heating
What is Induction Heating?
- Induction heating is a non contact method of precisely and accurately heating conductive materials. It is used in a variety of engineering and materials processing applications in the automotive, aerospace and engineering sectors.
What is an Induction Heater?
The induction heater typically consists of three elements.
- The Power Unit - Often referred to as the inverter or generator. This part of the system is used to take the mains frequency and increase it to anywhere between 1kHz and 400kHz. Typical output power of our systems are from 2kW to 500kW.
- The Work-Head - This contains a combination of capacitors and transformers and is used to match the power unit above to the work-coil.
- The Work Coil - Also known as the inductor the coil is used to transfer the energy from the power unit and work-head to the work-piece. Inductors Range in complexity from a simple wound solenoid consisting of a number of turns of copper tube wound around a mandrel to a precision item machined from solid copper brazed and soldered together. As the inductor is the area where the heating takes place coil design is one of the most important elements of the system and is a science in itself.
How does it work?
The process of Induction heating relies on the principle of electromagnetic induction. The principle dictates that when a conductive material is placed in a rapidly changing magnetic field a current will flow in this conductor. In the induction heater the component is placed in a cooper coil which has a rapidly changing magnetic field the component then effectively acts as the short circuit secondary winding of a transformer. The current flow thereby created combined with the resistance properties of the material creates a loss which is expressed as heat. In magnetic materials additional heat is generated below the curie point due to a magnetic loss know as hysterisis.
Why do you change the frequency?
The depth at which the current flows in the material is determined by various factors. These include the resistivity and relative permeability of the material, the frequency of the magnetic field and the power density. Frequency selection is based on many factors including the type of application (case hardening, forging brazing etc). The higher the frequency the shallower the depth of heat and the lower the frequency the deeper the depth.
How hot does the Induction Coil get?
As the heat is developed within the component being heated and not the coil the only heat seen in the coil is as result of its own electrical losses and the radiated heat from the component. For this reason the coil is water cooled.
What are the principle benefits of Induction Heating?
Due to the nature of the induction heating process it has a number of benefits over traditional methods as follows:
- No naked flame, gas bottles or explosive atmosphere safety issues.
- Reduced scale.
- Rapid focused heat.
- Reduced operator skill levels.
What is the Curie Point?
Magnetic steels have a temperature at which they lose their magnetic properties this typically occurs at around 750°C to 800°C.
Can Plastics be Induction Heated?
Induction heating can only directly heat conductive materials such as metals, carbon based materials etc. However there are many applications where induction heating is used to heat a metal part prior to insertion into a plastic.
What about non Magnetic Material?
Both magnetic and non magnetic metals can be heated. It is however easier to heat a magnetic material than a non magnetic due to the hysteresis loss. It should however be borne in mind that this effect ceases at temperatures above curie.
I am heating a small diameter magnetic wire on my induction heater and when it gets to 750°C it suddenly will not get any hotter?
This phenomenon is known as current cancellation. Due to changes in the materials relative permeability the depth of penetration in the material pre-curie is much less than post-curie. Once the current penetration is beyond a certain depth the current flow one way in the component cancels out the current going the other way therefore significantly reducing the heating effect. Often the radiated losses then outweigh the heat input leading to the phenomena you are observing.
What parameters affect the depth of penetration in the material?
The frequency of the power supply, resistivity of the material, power density and relative permeability all affect the depth of current flow in the material.
Please browse our website for more information about Induction Heating then contact us on 0114 272 3369 to speak to a member of our team or e-mail us on firstname.lastname@example.org.