Note: Heating Steel Coated Copper Wire
Objective:
Heat copper wire to 500 °F (260 °C) for a wire heating application; this client was looking to update their induction system.
End Product:
Copper wire
Equipment:
Ambrell EASYHEAT 10 kW, 150-400 kHz induction heating power supply with a workhead and coil specifically designed for this application.
Materials:
Steel coated copper wire, 0.1 in (2.54 mm) and 0.05 in (1.27 mm) diameters
Temperature:
500 °F (260 °C)
Frequency:
335 kHz
Testing:
A custom-designed single position multiple turn helical coil was built to generate the required heating for the application. Initial tests were conducted to optimize the power delivered to the part. Temperature indicating paint was then applied to the part, which dissolves when the part reaches target temperature. In static tests, it was observed that it took 2.5 seconds to heat an 11 in (279 mm) length of sample wire to temperature. This corresponded with the desired feed rate of 21 fpm (6.4 m/min. The speed was programmed to be 23 fpm (7.0 m) during testing to allow for an extra measure of confidence in its feasibility.
Benefits:
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Speed: Induction met the client's heating time objective.
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Repeatability: The client can expect the same result in the same amount of time every single time.
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Efficiency: Induction can efficiently heat the part in a controlled manner to only deliver the required heat.
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Footprint: Induction, with a movable workhead, is often more space efficient than other heating methods.
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