An induction melting furnace operates by utilizing electromagnetic induction to generate heat within the metal itself, thereby melting it. This process involves the use of an alternating current (AC) which flows through a coil, typically made of copper, to create a rapidly reversing magnetic field. This magnetic field penetrates the metal charge, inducing eddy currents within the metal. These eddy currents, flowing through the metal's electrical resistance, produce heat via Joule heating, which is the conversion of electrical energy into heat.
The frequency of the AC used is crucial as it determines the depth of penetration of the magnetic field into the metal. Higher frequencies result in shallower penetration, which is suitable for melting smaller or thinner pieces of metal, while lower frequencies can penetrate deeper, making them suitable for larger or denser metal charges.
Once the metal is heated to its melting point, the eddy currents continue to stir the molten metal, ensuring thorough mixing and a uniform temperature throughout the melt. This stirring action is beneficial for achieving consistent chemical compositions and temperatures in the final product.
The furnace itself consists of a power supply, an induction coil, and a crucible made of refractory materials. The crucible holds the metal charge, which acts as the secondary winding of a transformer. When the induction coil is energized with AC, it generates an alternating magnetic field that cuts across the metal charge in the crucible, inducing an electromotive force in the charge. This force generates the eddy currents responsible for the heating effect.
Induction melting furnaces are versatile and can be used to melt a variety of metals, including iron, steel, copper, aluminum, and precious metals. They are known for their efficiency, cleanliness, and precise temperature control, capable of reaching temperatures up to 2800°C. Different types of induction furnaces, such as coreless, channel, and crucible furnaces, are available and vary in size, capacity, frequency, and design to suit different industrial needs.
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