When a heating element stops working, it can be due to a variety of factors ranging from physical degradation to operational failures.
Understanding these issues is crucial for lab equipment purchasers to ensure the longevity and efficiency of their heating elements.
Below, we explore the key reasons why heating elements fail, drawing from the provided references.
7 Common Reasons Why Heating Elements Fail
1. Evaporation and Vapor Pressure
Mechanism: In vacuum environments, materials with high vapor pressure can evaporate, reducing the cross-sectional area of the heating element and leading to burnout.
Prevention: Use materials with lower vapor pressure for heating elements and consider partial pressure atmospheres above the critical evaporation temperature.
2. Mounting and Wiring Issues
Ceramic Insulators: These provide electrical isolation but are vulnerable to short-circuiting from carbon dust or metallic condensates.
Maintenance: Regular cleaning and inspection of insulators are necessary to prevent short-circuits.
3. Formation of Hot Spots
Local Oxidation: High rates of local oxidation can reduce the wire's cross-section, increasing resistance and causing localized overheating.
Shielding and Support: Improper shielding or insufficient support can lead to reduced heat loss and increased temperatures, causing hot spots.
Prevention: Use minimal supports and ensure proper spacing to avoid hot spots.
4. Oxidation and Intermittency of Operation
Oxide Scale Formation: Continuous oxide scale protects the inner metal but can crack and flake off with frequent thermal cycling, leading to increased oxidation and hot spots.
Maintenance: Avoid frequent on-off cycles to prevent oxide scale damage.
5. Embrittlement Due to Grain Growth
Material Brittle: Heating alloys containing iron can form large brittle grains at high temperatures, making the elements brittle and prone to rupture.
Handling: Careful handling is required to prevent damage.
6. Loose Connections and Damage to Components
Connections: Loose connections should be tightened or repaired immediately to prevent further damage.
Cleaning: Regular cleaning and bake-out cycles are necessary to maintain the integrity of the heating elements.
7. Environmental Factors
Humidity and Corrosive Gases: High humidity and presence of corrosive gases can corrode the heating elements, reducing their lifespan.
Prevention: Ensure proper environmental conditions and prevent exposure to corrosive substances.
8. Operational Control and Protection
Thermostat Control: Automatic temperature control systems are essential to prevent overheating.
Overload Protection: Use overload relays and fuses to protect against short circuits and other operational failures.
Maintenance: Regular checks and maintenance of control systems are crucial.
By understanding these key points, lab equipment purchasers can make informed decisions about the selection, operation, and maintenance of heating elements, thereby ensuring their reliability and longevity.
Continue Exploring, Consult Our Experts
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Our products are engineered to minimize evaporation, prevent hot spots, and endure harsh environments, ensuring your equipment operates at peak performance.
Don't let heating element failures disrupt your workflow.
Contact us today for expert advice and the perfect solution for your lab's heating element needs.
