A heating element can overheat. This can happen due to several reasons.
Can a Heating Element Overheat? 4 Key Factors You Need to Know
Exceeding Maximum Allowable Temperature
Heating elements are designed to work within certain temperature limits. If the temperature goes above the maximum allowed, the material can break down. This can lead to early failure or reduce the element's life. The element's temperature is usually higher than the furnace temperature. So, there needs to be a safety range of 50 – 200°C above the required temperature to avoid overheating.
Formation of Hot Spots
Hot spots are areas in the heating element that get hotter than the rest. These can happen due to local oxidation, which makes the element's wire thinner and increases resistance. This leads to more heat in that area. Supports around the element can also cause hot spots by reducing local heat loss. Other factors like high temperature, poor support, or wrong fuse material can cause the element to bend and create uneven spacing and hot spots.
Oxidation and Intermittency of Operation
At high temperatures, a protective layer forms on the heating element's surface. This layer prevents further oxidation. However, frequent heating and cooling can cause this layer to crack and fall off. This exposes fresh metal to oxidation and can lead to hot spots.
Embrittlement Due to Grain Growth
Heating alloys containing iron can form large, brittle grains at high temperatures. When cooled, these elements can become very brittle and may break easily. This brittleness can be worsened by overheating, leading to early failure of the element.
Preventing Overheating
To prevent overheating, choose heating elements with a high maximum temperature. Ensure proper support and spacing. Use appropriate materials and controls to manage temperature changes. Maintain the oxide layer's integrity and prevent exposure to corrosive gases to extend the element's life.
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