The coreless induction furnace is widely used for melting high melting point alloys, all grades of steels and irons, and various non-ferrous alloys. It is particularly favored for remelting and alloying due to its precise temperature and chemistry control, and the efficient circulation of the melt facilitated by induction currents.
Applications of Coreless Induction Furnace:
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Investment Casting: Coreless induction furnaces are extensively used in investment casting due to their versatility in handling a wide range of metals. They are available in both air and vacuum configurations, making them suitable for nearly all metals. The ability to shut down and start cold, as well as the flexibility to operate across a range of frequencies (50 Hz to 10 kHz), enhances their utility in this application, allowing for easy alloy changes and precise temperature control.
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Melting and Holding of Metals: These furnaces are designed for melting and holding both ferrous and non-ferrous metals, with capacities ranging from 1 t/h to 50 t/h and power ranges from 25 kW to 30000 kW. The coreless induction furnace has become a preferred choice over traditional methods like cupolas, which are known for emitting significant amounts of dust and other pollutants.
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Remelting and Alloying: The coreless induction furnace excels in remelting and alloying processes due to its high degree of control over temperature and chemistry. The induction current not only heats the material but also provides good circulation of the melt, ensuring even heat distribution and consistent alloy composition.
Construction and Operation:
The coreless induction furnace consists of a refractory vessel surrounded by a coil mounted on a steel frame. When an alternating current (AC) flows through the coil, it generates an electromagnetic field that induces eddy currents in the charged material, heating it according to Joule’s law and eventually melting it. The main components include a crucible, a power supply unit (transformer, inverter, and capacitor bank), charging arrangement, cooling system, process control system, and fume extraction equipment.
Efficiency and Flexibility:
While the absence of a flux-concentrating core reduces power efficiency compared to channel furnaces (approximately 75%), smaller coreless furnaces operate at higher frequencies, maintaining efficiency and promoting vigorous stirring action. This setup ensures that the furnace remains efficient despite its design limitations, making it a versatile tool in metallurgical processes.
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