The lifespan of a heating element can vary significantly depending on several factors including the material of the element, operating conditions, maintenance, and the design of the furnace. Generally, the life of a heating element is influenced by its resistance to grounding, the environment in which it operates, the integrity of its oxide layer, and the watt density it experiences.
Resistance to Grounding: Regular checks of the heating element's resistance to grounding are crucial, especially in furnaces used for specific processes like low-pressure vacuum carburizing. The resistance should typically be between 90 – 100 ohms. A drop to 10 ohms or less usually indicates failure. Over time, molybdenum elements and their insulators can metalize, reducing their resistance and leading to eventual failure.
Environmental Conditions: The heating element's life is also affected by the environment in which it operates. It should be used in conditions where the relative humidity does not exceed 85%, and there is no presence of conductive dust, explosive gas, or corrosive gas. When heating materials like grease, the release of volatile gases can corrode the heating elements, leading to a shorter lifespan. Proper sealing or ventilation of the container during heating can help prevent this.
Oxide Layer Integrity: The oxide layer on the surface of the heating element is critical for its longevity. Any damage to this layer can significantly shorten the element's life. Each shutdown of the furnace can damage the oxide layer, so it is recommended to avoid unnecessary shutdowns after the furnace has been started.
Watt Density: The watt density, or the power density, of the heating element is another key factor. This is the amount of power per unit area from which the heat is radiated. A higher watt density can lead to higher temperatures and potentially shorter element life. To extend the life of the heating elements, using a lower watt density by incorporating more elements in the furnace can be beneficial. However, this must be balanced against the increased cost and space requirements.
In summary, the lifespan of a heating element is determined by a combination of regular maintenance checks, appropriate environmental conditions, careful handling to preserve the oxide layer, and careful management of watt density. By adhering to these guidelines, the service life of heating elements can be maximized, ensuring efficient and prolonged operation of the furnace.
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