Heating elements are crucial components in various industrial and laboratory settings. However, they can fail due to several reasons. Understanding these causes can help in preventing failures and ensuring the longevity of your equipment.
10 Common Reasons for Heating Element Failure
1. Evaporation in Vacuum Chambers
When a heating element is exposed to a vacuum where the pressure is below the material's vapor pressure, it can evaporate. This reduces its cross-sectional area and leads to burnout, especially at higher temperatures. To prevent this, use materials with lower vapor pressures than the operating pressure in the furnace, or use partial pressure atmospheres above the critical evaporation temperature of the element material.
2. Mounting and Wiring Issues
Heating elements held in place by ceramic or quartz insulators can fail if these insulators are not kept clean. Accumulation of carbon dust or metallic condensates can lead to short-circuiting. Regular cleaning of these insulators, typically by heating them in air in a laboratory furnace, can prevent such failures.
3. Vacuum Leaks
Leaks in the vacuum system can lead to failures by affecting the operational environment of the heating elements. Regular checks and maintenance of seals and gaskets, tightening loose fittings, and replacing damaged components are essential.
4. Overheating
Damaged, worn, or faulty heating elements can lead to overheating, which is a common cause of failure. Proper temperature controller settings and regular inspection and replacement of elements can prevent this issue.
5. Power Supply Issues
Failures can occur due to issues with the power supply or wiring. Regular checks for damage or loose connections and maintenance or replacement of damaged components are necessary.
6. Gas Flow Issues
For furnaces using gas, improper gas flow or pressure can lead to element failures. Ensuring the gas supply is functioning correctly and checking valves and regulators for damage or leaks is crucial.
7. Formation of Hot Spots
Hot spots can develop due to local oxidation, shielding by supports, or incorrect fuse material selection, leading to uneven heating and eventual breakdown. Minimizing the number of supports and ensuring proper element temperature and support can help prevent this.
8. Oxidation and Intermittency of Operation
Frequent heating and cooling cycles can cause the oxide scale on the heating element to crack and flake off, leading to increased local oxidation and hot spots.
9. Embrittlement Due to Grain Growth
Heating alloys containing iron can form large, brittle grains, making the elements prone to rupture, especially when cold.
10. Contamination and Corrosion
Elements can be contaminated by gases, fumes from fluxes, or oil fumes, leading to dry corrosion and eventual failure.
Continue exploring, consult our experts
The most critical factors affecting the life of heating elements are the temperature of the hottest point and the ratio of intermittent to continuous working. Regular maintenance and monitoring of these factors can significantly extend the lifespan of heating elements.
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