Note: Heating a 10mm Diameter Steel Wire

Objective:

To heat a 10 mm diameter steel wire to 400 °F (204 °C) in a continuous process

End Product:

Steel wire

Equipment:

Ambrell EKOHEAT 10 kW induction heating system, equipped with a remote heat station containing three 1.0 μf capacitors (for a total capacitance of 3.0 μf).

Materials:

10 mm diameter steel wire

Temperature:

400 °F (204 °C)

Frequency:

98 kHz

Testing:

A specially designed helical induction coil was used to provide heat to the part.  Initial tests were conducted to optimize the power delivered to the part and to understand the heating patterns achieved. After several changes and iterations on the coil setup the following data is collected from the testing.
Heat time 0.5-1 seconds
A special 4 turn series inductor is needed along with the 7-8 turn induction coil to maximize the power delivery from the power supply.
Induction coil is 2.75in in length producing a 2 in long heat zone in about 1 second.
A feed rate of 10-12feet per minute is easily achievable with the Ambrell 15kW power supply

Benefits:

  • Repeatability: Induction delivers the same result every single time, making it a repeatable solution which is critical for this process.

  • Speed: Induction has no warm-up time like an oven and can quickly come up to temperature. Induction met the client's timing objectives.

  • Footprint: Induction takes up a modest amount of floor space, especially when you consider that the workhead can be placed a distance away from the power supply.

  • Safety: Not only is induction heating efficient, it also offers safety advantages as there is no open flame.

Heating a 10mm Diameter Steel Wire

Visit our Applications Lab to learn more about free applications testing.
1655 Lyell Ave, Rochester, NY 14606 USA | Tel: +1 585 889 9000