Induction melting solves complex industrial problems, such as using high melting-temperature alloys, like titanium, nickel-based alloys, and stainless steel. Faster than traditional fusion, induction melting ovens require as little as an hour. Single-touch operations considerably cut the cost of human labor and cycle time.
The Induction Melting Process
Induction melting starts with placing the metal into the magnetic field inside a furnace. Induction melting works by forcing electrical vortices into a piece of metal. The principle of induction melting is that a high-voltage electrical source from a primary coil causes a low-voltage, high-current flow of electricity to enter a metal or secondary coil. The magnetic fields induce electric vortices, circular currents, to take place inside the metal by electromagnetic induction.
With induction heating, the heat is efficiently distributed within a metal part as the electrical eddies circulate faster and faster inside the part. Because induction heating is accomplished using magnetic fields, a working interest (or load) can be physically isolated from an induction coil using refractory materials or other nonconductive media. When the charged material is melting, the interaction of the magnetic fields and electric current flowing through the coil continues to increase heat inside the metal until reaching the pre-set temperature. Melting temperature can be controlled by infrared or thermocouple.
The Induction Furnace
An induction furnace comprises a crucible to hold the metal pieces to be melted, enclosed by a copper coil. The crucible used in heat induction may or may not be conductive. Depending on the metal to be smelted, different crucibles are used. For example, if we want to melt iron which is found in many minerals such as haematite, then we would need a non-conductive crucible made from materials such as clay or glass because it would not allow heat energy to pass through it easily. However, if we wanted to melt copper which is found in minerals such as chalcopyrite, then we would need a conductive crucible made from materials such as carbon steel because it would allow heat energy to pass through it easily. If it is a conductive metal like copper or aluminum, then any crucible that can withstand extremely high temperatures will work well. If it is a non-conductive metal like gold or platinum, then a non-metallic crucible made from ceramic materials will be required to avoid electric shock from arcing between the crucible and the coil.
Benefits of Induction Melting
Applications of Induction Melting
Jewelry – FOCO’s Induction melting equipment meets the requirements of major manufacturers in the Jewelry Industry and can produce casts in all precious metals–gold, platinum, palladium, silver–as well as nonprecious metals such as stainless steel, titanium, and other metallic alloys.
Academic & Research – High-frequency induction heating devices are typically preferred choices for academic research applications. At FOCO, our R&D teams help meet your requirements considering every parameter of your project.
Foundries & Metalworking – Induction melting is this industry’s favored technique, providing a safe, energy-efficient, and cleaner process. Induction melting provides fast, effective, and repeatable results.
Semiconductor & Crystal Growing – In the manufacturing of semiconductors and crystal growth applications, the stability of induction melting has been a favorite technique in various crystal growing processes.
Aerospace and Defense – The aerospace and defense industries have specifications which making induction melting a preferred solution to many of their production requirements. FOCO has a wealth of experience developing the most challenging Induction Heating applications and manufacturing system requirements.
Types of induction furnaces:
Coreless Induction Furnaces
Coreless induction furnaces, like aluminum and steel shell furnaces, are typically used to fuse a wide range of grades of steel and iron and various non-ferrous alloys. The coreless furnace is ideal for melting and alloying because it has a high degree of temperature and chemical control. In addition, the induction current provides good circulation movement to the melt.