Induction Heating for Carbide Tipping
Induction Heating for Carbide Tipping
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Electric Heating & Welding
Part-2
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Arc Heating
• Heating the materials by means of electric arc
• Industrial arc furnaces working under arc heating
• Electrical arc furnace means an extremely hot enclosed space where heat is produced by means
of electric arcing for melting certain metals such as scrap steel without changing electro chemical
properties of the metals
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• It is desirable to operate the arc furnace at 0.7 power factor
• The arc furnace have conical shapes
• Two type of arc heating direct and indirect
Graphite electrodes
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• They are obtained by heating carbon electrodes to a very high temperature
• Owing to lower resistivity of graphite (one fourth of the carbon), graphite is required half in size
for the same current resulting is easy replacement
• Oxidation starts at about 600°C
Self - baking electrodes
• They are made of a special paste, the composition of the paste depends upon the type of
process for which it is employed
• When current is passed, heat is produced that bakes the paste to form an electrode
• Used production of Ferro-alloys, electro- chemical furnaces and in production of aluminium by
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electrolytic process
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Direct Arc Heating Additional exam specific points is session SE-2-Part-1_Video: 21.2
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Working of Direct ARC heating furnaces: ( for understanding purpose only )
• The space between the charge and electrode get ionized by Appling electric voltage in electrodes
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• To increase or decrease the arc length by moving the electrode upward and downward by a motor
• To control the voltage of arc a transformer is used with tapping in primary winding
• If the available supply is DC or 1-Φ AC, two electrodes are sufficient, if the supply is 3-Φ AC; three
electrodes are placed at three vertices of an equilateral triangle
• The most important feature of the direct arc furnace is that the current flows through the charge, the
stirring action is inherent due to the electromagnetic force setup by the current and such furnace is
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used for manufacturing alloy steel and gives purer product
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Advantages
• It produces purer products, when compared with other methods.
• It is very simple and easy to control the composition of the final product during refining process
Application
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• This type of furnace is to produce steel, alloy steel such as stainless steel etc.
• Used for the manufacture of grey iron casting
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Indirect Arc heating
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• This electric arc is used for melting the metal
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Working of Indirect ARC heating furnaces: ( for understanding purpose only )
• In indirect arc furnace, the arc strikes between two electrodes by bringing momentarily in contact
and then with drawing them heat so developed, due to the striking of arc across air gap is
transferred to charge is purely by radiation
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• These furnaces are usually single phase (1-Φ) and hence their size is limited by the amount of
one-phase load which can be taken from one point
• Since on this furnace current does not flow through the charge, there is no stirring action and the
furnace is required to be rocked mechanically
• The electrodes are projected through this chamber at each end along the horizontal axis. This
furnace is also sometimes called as Rocking Arc Furnace
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Working of Indirect ARC heating furnaces: ( for understanding purpose only )
• The charge in this furnace is heated not only by radiation from the arc between electrode tips but
also by conduction from the heated refractory during rocking action; so the efficiency of such
furnace is high
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• Power input to the furnace is regulated by adjusting the arc length by moving the electrodes
• Even though it can be used in iron foundries where small quantities of iron are required
frequently, the main application of this furnace is the melting of non-ferrous metals
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Advantages
• Lower overall production cost per tonne of molten material
• Sound casting in thin and intricate design can be produced
• Metal losses due to oxidation and volatilization are quite low
• Flexible in operation
Disadvantage
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• No inherent stirring action as there is no current flow through the charge
• Continuous rocking should be done to distribute heat uniformly
Application
• The arc furnaces are used to produce mini steel structural bars and steel rods
• The main application of this type furnace is melting of non-ferrous metals
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C) Electron bombardment heating
• The electrical heating process used is electron bombardment of a refractory metal heat exchange
by ac celebration of electrons from an emitter to collecting surface heating occurs at the heat
exchanger surface by impingement of electron
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• Bombardment of electron causes heating
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Types: High Frequency Heating
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2. Dielectric Heating (or Electronic Heating or Radio Frequency Heating )
(Electrically insulating Materials)
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1. Induction Heating or eddy current heating
Induction heating is the process of heating an electrically conducting object (usually a metal)
by electromagnetic induction, through heat generated in the object by eddy currents
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• An induction heater consists of an electromagnet and an electronic oscillator that passes a
high frequency alternating current (AC) through the electromagnet
•
The rapidly alternating magnetic field penetrates the object, generating electric currents inside
the conductor, called eddy currents
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• The eddy currents flowing through the resistance of the material heat it by Joule heating
• An important feature of the induction heating process is that the heat is generated inside the
object itself
To develop sufficient amount of heat the resistance of material must be low and the voltage
must be higher, which can be obtained by employing higher flux and higher frequency
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• If the charge is non magnetic, then the heat developed due to eddy current loss
• If the charge is magnetic material there will be hysteresis loss in addition to eddy current loss
• Both the hysteresis and eddy current loss depends upon frequency ,but in high frequency
hysteresis loss is very small as compeered to eddy current
KPSC Question
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Applications of Induction Heating
2. Zone refining used in the semiconductor industry ( Kerala PSC, SSC JE**)
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3. To melt refractory metals that require very high temperatures
4. It is also used in induction cook-tops for heating containers of food; called Induction Cooking
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Type of Induction Furnaces
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Direct Core Type
The core type furnace is essentially a transformer in which the charge to be heated forms single turn
secondary Circuit and is magnetically coupled to the primary by an iron core
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• The magnetic coupling between primary and secondary is
very weak, it results in high leakage reactance and low pf
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• It is an improved form of direct core type, this furnace consists of a vertical core instead of
horizontal core it is also called Ajax-Wyatt induction furnace
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• This furnace is very suitable for continuous operation
• Vertical core avoids the pinch effect due to the weight of the charge in main body of the crucible
• The leakage reactance is comparatively low and the power factor is high as the magnetic
coupling is high compared to direct core type
• It is suitable for continues operation and widely used for melting and refining of brass and other
heavy non ferrous metals
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• Its efficiency is about 75 percent
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Indirect Core Type Furnace
• This type of furnace is used for providing heat treatment to metal
• The secondary winding itself forms the walls of the container or furnace and an iron core
links both primary and secondary windings.
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• The heat produced in the secondary winding is transmitted to charge by radiation
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Indirect Core Type Furnace : Principle of working Refer session: 21.2
• It consists of magnetic circuit AB is made up of a special alloy and is kept inside the chamber of the
furnace.
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• This magnetic circuit loses its magnetic properties at certain temperature and regains them again
when it is cooled to the same temperature
• When the oven reaches to critical temperature, the reluctance of the magnetic circuit increases many
times and the inductive effect decreases thereby cutting off the supply heat
• The magnetic circuit is detachable type that can be replaced by the other magnetic circuits having
critical temperatures ranging between 400°C and 1,000°C
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Coreless Type Induction Furnace
• It is simple furnace with the absence core
• The furnace consist of refractory or ceramic crucible cylindrical in shape enclosed within a coil
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that forms primary of the transformer
• The furnace also contains a conducting or non contacting container that acts as secondary
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• If the container is made up of conducting material charge can be conducting or non conducting
• If the container is made up of non contacting material charge taken should have conducting
properties
• When primary coils are excited by an alternating source, the flux set up by these coils induce the
eddy currents in the charge
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• These currents heat the charge to melting point and they also set up electromagnetic forces that
produce a stirring action to the charge
• In coreless furnace, the flux density will be low as there is no core. Hence, the primary supply
should have high frequency for compensating the low flux density
• If it is operating at high frequency, due to the skin effect, it results in copper loss, thereby
increasing the temperature of the primary winding
• All this necessitates artificial cooling. The coil, therefore, is made of hollow copper tube through
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which cold water is circulated
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2. Dielectric Heating (or Electronic Heating or Radio Frequency Heating )
• A dielectric material is an electrical insulator that can be polarized by applied electric field
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• An important property of a dielectric is its ability to support an electrostatic field
• A dielectric material is a substance that is poor conductor of electricity but an efficient supporter
of electrostatic field
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Dielectric Heating (or Electronic Heating or Radio Frequency Heating )
Dielectric heating is the process in which a radio frequency (RF) alternating electric field, or radio
wave or microwave electromagnetic radiation heats a dielectric material. At higher frequencies, this
heating is caused by molecular dipole rotation within the dielectric
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• Dielectric heating involves the heating of electrically insulating materials by dielectric loss
Frequencies in the range of 10–100 MHz are necessary to cause dielectric heating
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• In dielectric heating the heat is produced within the material itself. This results in uniform heat
generation and thus dielectric material is heated uniformly
• Dielectric Heating is the only heating technique which operates at leading power factor
** KPSC,SSC
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Dielectric Losses
• When insulating material is subjected to an alternating field the atom gets stresses
due to the inner atomic friction hence heat is produced
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• All the dielectric material are consider to be imperfect
capacitor and can be represented in form of Resistance R
and Capacitor C in parallel
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Dissipated power loss is proportional to • All the dielectric material are consider to be
imperfect capacitor and can be represented
in the form of
frequency f and Resistance R and Capacitor C in parallel
square of voltage
Additional exam specific points is
𝑽𝟐 session**
SE-2-Part-1_Video: 21.2
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loss tangent
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IR 𝑉
tan 𝛿 = Power =
𝐼𝑐 𝑅
Ic = 𝝎𝒄𝑽
𝑉2
𝑣 Power = 1
tan 𝛿 = 𝑅
𝜔Ctan 𝛿
𝑉
tan 𝛿 = 1
𝜔𝑐
𝜔𝑅𝐶
SCORE ACADEMY 𝑽
Ir = 𝑹
Power = 𝑽𝟐 𝒕𝒂𝒏 𝜹 𝑪𝝎
1
R=
𝜔C tan 𝛿 Power = 𝑽𝟐 𝒕𝒂𝒏 𝜹 𝑪𝟐𝝅𝒇
Dissipated power loss is proportional to frequency (f) and square of voltage (𝑽𝟐 )
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Advantages of dielectric heating
• No necked flame appears
• By increasing frequency heating become faster
• Heating can stopped by immediately
• Uniform Heating
• Plastic and wooden product can be safely heated
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Relevant Questions for Kerala PSC, SSC, RRB
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6. Which of the following heating element will have the least temperature range?
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a) Copper b) Aluminium
c) Nichrome d) Eureka
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1 a
11. For radiant heat around 2000c° the heating element used is? 2 a
a) Tungsten alloy b) Copper alloy 3 b
c) Carbon d) Nichrome
4 c
12. The arc furnace of conical shapes have the advantages of ? 5 d
a) Large surface area b) low power consumption 6 d
c) Reduced radiation losses d) All the above
7 c
13. The main application of indirect arc furnace is to melt? 8 d
a) Iron b) Steel 9 a
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c) Non-ferrous metals d) non of the above 10 c
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16. A perfect black body is one which ?
a) Absorb all incident radiation
c) Transmits all incident radiation
b) Reflect all incident radiation
d) All the above
17. For the transmission of heat from one body to another it is essential that?
a) Both body are solid b) the two body are different temp
c) Both body are in contact d) Non of the above Detailed exam specific points and explanation
to these questions in session**
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19. Fourier's Law deals about ?
a) conduction b) Convection
c) Radiation d) All the above Answer Key
11 a
20. Stephan's law deals about rate of heat transfer by ?
a) conduction b) Convection 12 d
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c) Radiation d) All the above 13 c
14 a
21. Dielectric heating is also called ?
a) Volume heating b) Infrared heating 15 d
c) Surface heating d) Eddy current heating 16 a
17 b
22. Furnaces used for cremation ?
a) Dielectric heating b) Arc heating 18 d
c) Resistance heating d) Eddy current heating 19 a
Detailed exam specific points and explanation 20 c
to these questions in session**
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Video: 21.1 ,Video: 21.2
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Answer Key
23. Hysteresis loss and eddy current loss are used in?
a) Dielectric heating b) Resistance heating 21 a
c) Inductive heating d) Arc heating 22 c
23 c
24. In an electric heating the metal case is connected to?
a) Phase wire b) Earth wire 24 b
c) Neutral wire
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d) Non of the above
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27. Which of the following heating methods has maximum power factor? ** key as per SSCJE
a) Dielectric heating b) Arc heating
c) Resistance heating d) Eddy current heating
28. Which of the following will happen if the thickness of refractory wall of furnace is increased?
a) Heat loss through furnace wall will increase b) Temperature inside the furnace will fall
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c) Temperature on the outer surface of furnace walls will drop d) Energy consumption will
increase
29. The material of the heating element for a furnace should have?
a) temperature co-efficient b) High specific resistance
c) Lower melting point d) All of the above
30. By which of the following methods the temperature inside a resistance furnace can be varied?
a) By varying the operating voltages b) By varying the current through heating elements
c) By disconnecting some of the heating elements d) By any of the above method
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31. The material to be used for heating element should be of high resistivity so as to? SCORE
a) Increase the life of heating element b) Reduce the length of the heating element
c) Reduce the effect of oxidation d) Produce large amount of heat
32. Which of the heating element can give highest temperature in resistance heating?
a) Nichrome b) Silicon carbide
c) Copper d) Ni,Cr,Fe
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33. For temperature control in resistance furnaces resistance variation can be affected by connecting
resistance element in?
a) series or parallel b) series-parallel
c) Star or Delta d) Any of the above
34. The simplest and most commonly used method for temperature control is ?
a) External resistance in heating circuit b) Changing the connection of heating circuit
c) Use variable number of heating element d) Transformer tapping
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35. The device necessarily used for automatic temperature control in a furnace is ? SCORE
a) Thermostat b) Auto-transformer
c) Thermocouple d) Any of the above
Answer Key
36. The temperature inside of a furnace is measured by ?
a) Mercury thermometer b) Optical pyrometer 31 d
c) Alcohol thermometer d) Any of the above 32 b
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37. The control of salt-bath furnace is affected by ?
a) Varying the depth of immersion of electrode
b) Varying the distance between the electrode
33
34
35
d
b
a
c) Both a & b d) None of the above
36 b
38. Resistance oven used for ? 37 c
a) Domestic & commercial heating b) Electrical oven 38 d
c) Drying the varnishing d) All the above 39 d
39. It is desired to keep the arc length short in order to ? 40 c
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a) Have better heating b) Reduce the oxidation
c) Increase the life of roof refractory d) All the above
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40. Low frequency is necessary for direct core type induction furnace because ?
a) magnetic coupling is poor b) Pinch of effect occur
c) ) Both a & b d) None of the above
c) F
b) 1/F
d) 𝑓 2
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42. In induction heating the depth up to which current will penetrate is proportional to ?
a) 1/𝑓 .5
43. High frequency induction heating is used for ? Detailed exam specific points and explanation
to these questions in session**
a) Ferrous metals only b) Non ferrous metals only
c) Both ferrous and non ferrous d) None of the above SE-2-Part-1
Video: 21.1 ,Video: 21.2
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44. The dielectric loss in a dielectric material is proportional to ?
a) 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 2 b) Voltage
c) 1/ Voltage d) 𝑣𝑜𝑙𝑡𝑎𝑔𝑒
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c) ) Arc heater d) Dielectric heater
46. Hysteresis loss and eddy current loss are used in?
a) Resistance heating b) Dielectric heating
c) Induction heating of steel d) Induction heating of brass
Detailed exam specific points and explanation
47. Method of heating used for non-conducting metals ? to these questions in session**
a) Induction heater b) Resistance heater
SE-2-Part-1
c) ) Arc heater d) Dielectric heating Video: 21.1 ,Video: 21.2
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a) Induction heater b) Resistance heater 43 c
c) ) Arc heater d) Dielectric heating
44 a
50. Which furnace is know as Ajax wyatt furnace ? 45 b
a) Vertical core type b) Direct core type 46 c
c) ) coreless type d) Indirect induction 47 d
Detailed exam specific points and explanation 48 c
to these questions in session**
49 d
SE-2-Part-1
Video: 21.1 ,Video: 21.2
50 a
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Heating Type Application Electrodes Working Power
used principle factor
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Silicon carbide
Alloy of Tungsten
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Heating Type Application Electrodes used Working Power
principle factor
Carbon electrodes
Melting steel, alloy steel such as Graphite electrodes
Direct Arc stainless steel Self – baking Electrical Low pf
Arc Heating
Heating
Indirect SCORE ACADEMY
Melting of non-ferrous metals
electrode
Carbon electrodes
Graphite electrodes
Arc
Electrical
(lagging)
Low pf
Arc Self – baking Arc (lagging)
Heating electrode
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Heating Type Application Working Power
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principle factor
Core Direct Heat treatment in metallurgy Electromagnetic
type Induction
Vertical Zone refining used in the
Induction or
semiconductor industry
Heat formation Low pf
Heating Ajax-wyatt due to Eddy (Lagging)
To melt refractory metals that
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Indirect require very high temperatures current
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