What Is Induction Heating And How Does it Work?
October 24, 2024
Induction heating is a process where a metal object, whether magnetic or non-magnetic, is heated by placing it in a fluctuating magnetic field, known as eddy currents. To visualize this, imagine passing an alternating current through a round copper coil, generating a magnetic field within the coil.
When a metal object, referred to as a solenoid in this context, is placed inside the coil, the magnetic field wraps around the workpiece at a rapid pace. The speed of this wrapping is determined by the frequency of the applied RF (radio frequency) field.
As the magnetic field continuously "spins" around the metal, it begins generating heat within the workpiece. This occurs because metals have inherent electrical resistance, which causes the magnetic field to create friction inside the metal. This friction produces heat on the metal’s surface—a phenomenon known as the skin effect. The longer the metal remains in the magnetic field, the more the heat will penetrate deeper into the material through conduction.
Induction heating is just one of several methods for heating objects, with common alternatives including gas furnaces, electric furnaces, and salt baths. These traditional methods rely on heat transfer from a heat source (such as a burner, heating element, or liquid salt) to the product via convection and radiation. Once the surface of the product is heated, the heat is conducted through the material.
In contrast, induction heating does not depend on convection or radiation for delivering heat to the product. Instead, it generates heat directly within the surface of the material through the flow of electric current. This heat is then transferred throughout the material via thermal conduction.
The depth at which heat is generated in the material depends on a parameter known as the electrical reference depth. This depth is influenced significantly by the frequency of the alternating current applied to the workpiece: higher frequency currents produce a shallower electrical reference depth, while lower frequency currents result in a deeper reference depth. Additionally, the electrical and magnetic properties of the material also affect this depth.
- Non-Contact, Clean Heating: Induction heating offers a flameless, fume-free method to heat workpieces, eliminating the need for storing highly flammable materials like oxyacetylene torches.
- Production Data Logging: Induction heating systems allow for data logging of power versus time or temperature. This means you can record and monitor your heating processes, creating your own "secret sauce" production recipes stored securely on a digital card.
- Quick Access to Quality Control Data: Pre-qualified production recipes for different part diameters can be accessed quickly, ensuring consistent quality.
- Instant Power Availability: The induction system can be turned on only when needed, offering fast and immediate power at any time.
- Consistent and Repeatable Heating: Induction heating ensures that the same amount of heat is applied to the workpiece every time, offering consistency and repeatability in your processes.
- Durable Equipment: The water-cooled induction coil and power supply are built to last for many years, with no parts to wear out.
- Highly Regulated Output Power: The output power is finely regulated, ensuring consistent heat application to the workpiece.
- Fast Operator Training: Induction heating systems are easy to learn and operate, reducing training time.
- Portability: In many cases, the induction power supply is portable and can be moved easily on a cart from one workstation to another.
Here are a few key applications of induction heating:
- Induction Brazing: Replace traditional flame torches with a clean, precise, and non-contact method for brazing joints.
- Induction Soldering: Ideal for soldering RF contacts, potentiometer wiper contacts, or pre-tinning wires. We can also perform feasibility tests for your specific applications.
- Induction Bonding & Curing: Use induction heating for bonding applications and curing adhesives efficiently and effectively.
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