Luoyang HongtengIntermediate frequency induction furnace
Trempe et refroidissement Clearly, quenching and cooling are an essential part of the induction hardening process. Natural cooling is rarely used due to its slowness; most quenching uses forced cooling with water, oil, brine, or moving air. Crystal is most commonly used due to its excellent thermal conductivity. Single-shot quenching involves heating the entire surface to be quenched simultaneously, then immersing the workpiece in a quenchant or spraying the quenchant over the entire heated surface. Travel quenching utilizes a small induction coil for localized heating. The coil moves relative to the heated surface, quenching immediately after heating. This method allows a small coil and relatively low power to heat a large surface within a single heating cycle. This article describes the basic types of quench coolers used in induction heating. Trempe par induction This article describes travel quenchers and water spray coolers. This article shows a flat-surface water spray cooler, This article shows a circular-surface water spray cooler. The induction coil, water cooler, and workpiece are arranged in a moving, scanning pattern to create an optimal heating/cooling cycle. The water jet angle of incidence is critical, requiring a 50° angle to ensure uniform cooling and a uniform hardened layer depth...
The principles for selecting steel for induction hardening are similar, but not identical, to those for steel hardened by other methods. The hardenability of ordinary carbon steel increases with increasing carbon content. For example, steel with a 0.2% carbon content, or 1020 steel, can only be hardened to HRc 48, while steel with a 0.45% carbon content, or 1045 steel, can be hardened to HRc 60. Adding alloying elements such as chromium, nickel, molybdenum, and tungsten can improve the hardenability of steel by shifting the ridge of the S-curve to the right. Induction hardened steel For example, during through hardening, ordinary carbon steel requires rapid cooling or quenching rates to avoid the ridge of the S-curve and prevent softening. Due to slow heat conduction and slow cooling, the inner layer beneath the surface hardened layer may soften due to incomplete martensitic transformation. Even during surface hardening, heat conducted from the center of the workpiece to the surface tends to slow the surface cooling rate, similar to the effect of forming a soft pearlite surface. Quenching with a quenchant more intense than oil often results in excessive deformation. Therefore, by adding a small amount of alloying elements, oil quenching can...
Principles of Metallurgy This article presents a simplified equilibrium diagram for low-carbon steel. Below 721°C, the normal structure of carbon steel with a carbon content of 0.3-0.83% is pure iron (ferrite) + pearlite (pearlite is a mixture of lamellar ferrite and cementite). If the temperature rises above 721°C (the so-called Ac line), cementite begins to dissolve into solid solution. Upon reaching the Ac line, the entire material transforms into austenite—a solid solution with a crystal structure completely different from that of the original ferrite. Rapid surface cooling to 350/200°C avoids the reformation of the original ferrite and pearlite, allowing for direct passage through the martensite phase. Rapid carbon precipitation from the remaining martensite results in interlocking crystals within a fine, hard structure, resulting in a hardened austenite. Very hard steel. This rapid cooling method is called quenching (see §3.2). For high-carbon steel (0.8-1.7% carbon), the amount of martensite crystals increases, making the steel harder. Such steels should not be heated all the way to the Acm line; instead, they should be heated to a lower temperature, such as the quenching temperature, and then cooled from this temperature. The required quenching heating temperatures are shown in this article. If quenching cooling...
Traveling Wave Induction Heating: Principles, Applications, and Advantages Introduction When it comes to high-power induction heating applications, the use of single-phase induction coils often proves insufficient. For larger loads and better power balance, three-phase power supplies are typically applied. Although these setups do not represent a “true” three-phase system, they allow engineers to achieve higher efficiency in industrial induction heating systems. However, conventional multi-layer induction coils face challenges. The outer layers of the coil naturally heat the inner layers, leading to reduced power factor due to the increased air gap between the outer coil and the workpiece. While external flux-guiding techniques exist, they cannot effectively eliminate this limitation. To overcome these drawbacks, researchers at Aston University, Birmingham, have been developing an innovative solution: traveling wave induction heating. This emerging method promises to revolutionize the field and expand applications across multiple industries. The Principle Behind Traveling Wave Induction Heating The concept is best understood by drawing parallels with a traditional three-phase induction motor: In a standard motor, windings are distributed in multiple slots. When connected to a three-phase power source, these windings generate a sinusoidally distributed magnetic motive force (MMF) that rotates at a certain synchronous speed. The synchronous speed n...
Induction Furnace Melting Steel: My Real-World Grind Testing the Best for Your Ops in 2025 Hey there, steel melter—yeah, you, the one who’s probably elbow-deep in a failed pour right now, staring at lumpy slag and wondering why your setup keeps overheating or wasting power like it’s going out of style. I feel ya, pal. I’ve been exactly where you are. Back when I was ramping up my small casting shop, I’d spend nights cursing my old rig that couldn’t hit consistent melts for steel without burning through energy or risking a blowout. “Why does this have to be such a headache?” I’d gripe to my buddy over beers after another botched batch. As someone who’s clocked years testing gear for everything from hobby pours to industrial runs, I know the frustration of sifting through junk to find something reliable. So, I hunkered down, burned through my budget on trials (and a few crucibles), and narrowed it down to the real MVPs for induction furnace melting steel. If you’re hunting solid setups for clean, efficient steel melts—whether for scrap recycling or precision casting—hang tight. I’ll spill my unfiltered test notes, the highs and lows, and why I’m rock-solid confident these...
Reactor coils After passivation, high-quality copper tubes are wrapped with high-voltage-resistant insulation material. After forming using specialized tooling, the entire tube is wrapped with high-temperature, high-voltage insulation material. This ensures a high breakdown voltage and a long service life. A reactor, also known as an inductor, generates a magnetic field within the space it occupies when current flows through a conductor. Therefore, all current-carrying conductors generally exhibit inductance. However, the inductance of a long, straight conductor carrying current is small, and the magnetic field generated is weak. Therefore, a typical reactor is a solenoid formed by winding wire, known as an air-core reactor. Sometimes, to increase the inductance of this solenoid, an iron core is inserted, creating an iron-core reactor. Reactance is categorized into inductive reactance and capacitive reactance. The more scientific classification is that inductive reactance (inductors) and capacitive reactance (capacitors) are collectively referred to as reactors. However, because inductors existed first and were called reactors, the term “capacitor” today refers specifically to inductors, while “reactor” refers specifically to inductors. Product Description: Reactor coils are made from high-quality copper tubes that have undergone a passivation treatment and are then wrapped with high-voltage-resistant insulation material. After forming using specialized tooling,...
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