Heating elements are essential components in various applications, from household appliances to industrial furnaces. The manufacturing process varies depending on the material and specific application. Here’s a detailed look at how different types of heating elements are made.
1. Silicon Carbide Heating Elements
Manufacturing Process
Silicon carbide heating elements are produced by fusing high-purity grains of silicon carbide(SiC) heating element together. This is done through either a reaction-bonding process or a recrystallization process, which involves temperatures exceeding 3900°F (2150°C).
Shape and Application
These elements are typically tubular or cylindrical and are widely used in the heat-treating industry where high temperatures and maximum power are required.
2. Tubular Heating Elements
Composition
Tubular heating elements consist of a fine coil of Nickel Chromium Alloy (NiCr) Sputtering Target / Powder / Wire / Block / Granule resistance heating alloy wire located within a metallic tube, usually made of copper or stainless steel alloys like Incoloy. The wire is insulated by magnesium oxide powder.
Manufacturing Steps
The tube is drawn through a die to compress the powder, enhancing heat transmission. The ends are sealed with insulating materials like Aluminum Oxide (Al2O3) Ceramics Heat Sink - Insulation or silicone rubber to prevent moisture ingress.
Shapes and Uses
These elements can be straight rods or bent to specific shapes, used in appliances such as toaster ovens, electric stoves, ovens, and coffee makers.
3. Composite and Screen-Printed Heating Elements
Composite Elements
These elements involve screen-printed metal-ceramic tracks deposited on ceramic-insulated metal plates, commonly used in domestic appliances like kettles.
Advantages
This technology has been popular since the mid-1990s due to its efficiency and suitability for various heating applications in household appliances.
4. Heating Elements for Vacuum Furnaces
Metal Heating Elements
These include precious metals like molybdenum, platinum, tungsten, and general metals like nickel-chromium heat-resistant alloys. Each type is chosen based on the specific high-temperature requirements of the application.
Non-Metallic Heating Elements
These include graphite and various compounds like silicon carbide and molybdenum silicide. Graphite is particularly favored due to its excellent machinability, high-temperature resistance, and good resistance to thermal shock.
5. Material Selection and Cross-Sectional Area
Resistance and Heat Output
The selection of heating elements involves choosing materials and cross-sections that provide the appropriate electrical resistance to generate the desired heat output. The resistivity of the material and the cross-sectional area are critical factors.
Application-Specific Designs
For instance, in vacuum furnaces, heating elements are often wide strips or ribbon-shaped to maximize both their physical and radiant surface areas, ensuring efficient heat transfer and longevity.
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