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Cover Feature | Induction Heat Treating

10 Considerations When Selecting an Induction

Heating System

Induction heating bar end for fastener hot Induction

Induction heating has considerable advantages over other common heating

August 5, 2016 methods in speci c applications. Is yours one?
Brett Daly
 

Induction heating offers many bene ts to manufacturing processes because it is a rapid, energy-ef cient,
ameless method of heating electrically conductive materials. A typical system involves an induction
power supply, workhead with a copper coil and a chiller or cooling system. Current ows through the coil
to create an electromagnetic alternating eld. When a conductive part is placed inside the coil, current is
induced to run through it. Current ow combined with the resistance properties of the conductive part
results in heat generation.

It is critical to select the right system for your application and its requirements. An overpowered system
may mean you will spend more than you need to, while an underpowered system may lengthen your
heating process and slow down production. Here are 10 factors to consider when selecting an induction
heating system.

1. Your Part’s Material

Induction directly heats conductive materials such as metals. Nonconductive materials are sometimes
heated with a conductive susceptor. Due to hysteresis, magnetic materials are heated more easily than
nonmagnetic materials; consequently, nonmagnetic materials often require more power. Metals with high
resistivity like steel heat quickly, while low-resistivity metals like copper or aluminum require more
heating time.

2. Depth of Heating Penetration

The induced current will be most intense on the surface of your part. In fact, more than 80% of the heat
produced in the part is produced on the “skin,” or surface. Consequently, larger parts and parts that require
through-heating take more time to heat than those that are thin or small.

3. Operating Frequency
Lower-frequency, higher-power systems are generally suited for heating larger parts that require through
heating. Lower-power, higher-frequency systems are often the right choice for surface heating. As a
general rule, the higher the frequency, the shallower the heating of the part.

4. Applied Power
The output power of your induction heating power supply determines the relative speed at which your part
is heated. The mass of the part, rise in temperature and heat losses from convection and conduction need
to be considered. Often, the induction equipment manufacturer can help you make this assessment.

5. Rise in Temperature Required

Induction can generate a signi cant change in temperature, but, generally speaking, more power is needed
to accommodate a signi cant temperature change and will impact your power-supply choice. The rate of
temperature change also affects your power-supply choice. The faster the rate of change, the more
signi cant the power requirement.

6. Coil Design
Your coil, which is generally water-cooled and made of copper, needs to follow the shape of your part and
take the variables of your process into account. An optimal coil design will deliver the right heat pattern to
your part in the most ef cient way. A poorly designed coil will heat your part more slowly and deliver an
improper heating pattern. Flexible coils are now available and work well with large parts and unique part
geometries.

7. Coupling Ef ciency
The part being closely coupled with the coil elevates the ow of current, which increases the amount of
heat generated in the part. Coupling enables faster and more ef cient heating, which can increase
manufacturing ef ciency. Poor coupling has the opposite effect.

8. Your Facility and the Footprint

Induction requires cooling from a chiller or cooling system. Lower-power systems generally require a
compact water-to-air heat exchanger, while a higher-power system may require a larger water-to-water
heat exchanger or chiller. Additionally, you will need space for the induction heating power supply and
workhead. Generally speaking, an induction system will save considerable space over an oven, especially
when you consider that the workhead can be placed a signi cant distance away from the power supply. Of
course, you also need to be sure your facility can handle the amount of power the system requires.

9. Additional Heating Requirements

Will you need to measure and store heating data? Some induction solution providers can offer a full
system that includes an optical pyrometer and temperature-monitoring software so such data can be
recorded and stored. A comprehensive solution can lead to a smooth installation and start-up.

10. Industrial Expertise

Many induction manufacturers have expertise with certain applications, and if they’ve worked with your
application, it will provide peace of mind. Additionally, some providers offer laboratory testing and a
tailored system recommendation based on your heating requirements. This type of service takes the
guesswork out of selecting a system and helps you account for the aforementioned factors.

In conclusion, induction heating has considerable advantages over other common heating methods.
Buying the right system for your application’s needs and ensuring it meets any needs you may have for it
in the future will help your company fully bene t.

For more information: Contact Brett Daly, marketing specialist at Ambrell, an Ameritherm Co., Scottsville,
N.Y.; tel: 585-889-9000; web: www.ambrell.com.

Brett Daly is with Ambrell, an Ameritherm Co.; Scottsville,

N.Y.
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