Induction heating works based on the principle of electromagnetic induction, which is a phenomenon discovered by Michael Faraday in 1831. The basic idea behind electromagnetic induction is that when you place a conductor in a changing magnetic field, you create an electromotive force (EMF), which induces an electric current. This current, in turn, generates heat due to resistance.
Passing a high-frequency alternating current through an induction coil creates a changing magnetic field around the coil. When a conductive material, such as metal, is placed inside the magnetic field, the material produces eddy currents due to the changing magnetic field. These eddy currents generate heat based upon the material's electrical resistance. The frequency of the alternating current is a crucial factor in induction heating. The higher the frequency, the deeper the heat is generated in the material and the faster the heating process. Typically, frequencies in the range of 100-500kHz apply to induction heating. The heating process is controlled by adjusting the strength and frequency of the magnetic field and by controlling the position of the induction coil relative to the heated material. Controlling these parameters makes it possible to heat the material precisely and uniformly without heating the surrounding area.
To summarize, induction heating generates eddy currents in a conductive material through electromagnetic induction, which produces heat due to the material's resistance. Precise heating is a function of adjusting the magnetic field's strength, frequency, and position.
Industrial induction heating systems are used for various purposes in manufacturing, like surface hardening, brazing, welding, melting, and forging, among others.
Examples of industries that use induction heating in their processes are:
- Automotive industry - for engine parts' surface hardening and brazing fuel lines.
- Aerospace industry - for welding titanium components, heat treating blades and vanes, and brazing aluminum components.
- Metal fabrication industry - for forging, hardening, and welding of steel parts.
- Jewelry industry - for melting gold and silver alloys to make jewelry.
- Energy industry - for heating tubes and pipes in heat exchangers and boilers.
- Medical industry - for sterilizing medical instruments and welding stainless steel components.
- Electronic industry - for soldering and brazing of electronic components and assemblies.
Industrial induction heating systems are versatile and efficient heat sources with various applications across various industries. They provide fast, controlled, and uniform heating without requiring direct contact with the heated material, making them an attractive option for many applications.
Ambrell manufactures induction heating solutions for almost any application. Systems are available from 1 kW to 500 kW with various frequency options. Ambrell also offers an array of work head choices and optional accessories such as water cooling systems, induction heating software, and flexible induction coils.
For more information about Ambrell products in New England, contact AP Corp.
(508) 351-6200