Induction preheating of brass rods before hot forging

PUBLISHED: 08 Dec 15

The custom 10 turn induction coil is connected to the HS-100LF, with one brass rod in the coil
The custom 10 turn induction coil is connected to the HS-100LF, with one brass rod in the coil

The customer's current process uses resistive ovens to heat brass rods. The customer wants to improve safety and productivity, and reduce energy costs, by using induction instead of resistive heating. To maximize productivity, they want to be able to heat 3 brass rods at a time to 780°C within 25 seconds. For this application test, we are only heating one rod, so our goal is to heat the single rod to 780°C within 25 seconds with less than 30 kW of power. This will ensure that when heating 3 rods, that the 100 kW system will meet the production requirements.

Equipment

UPT LN100/50 100 kW Induction Heating Power Supply, operating between 10-50 kHz
HS - 100LF Low Frequency Heat Station

Materials

  • Brass rod
  • Custom coil, 10 turns, D=50mm, designed and manufactured by UltraFlex Power Technologies for this specific application - capable to heat 3 rods at a heat cycle.

Key Parameters
Temperature: 780°C
Power: 20 kW
Voltage: 380 - 480 V
Time: 24 sec
32 kHz

Process:

  • The UPT LN100/50 Power Supply was connected to the HS-100LF Heat Station.
  • The custom Coil was attached to the Heat Station.
  • The Brass rods were placed inside the Coil.
  • The Power Supply was turned on.
  • The UPT LN100/50 operating at 20 kW was able to successfully heat the single brass rod within 24 seconds, which was less than the 25 second time requirement established for the test. Three brass rods are expected then to heat within 25 seconds with approximately 60 kW of power (3 rods will be 3x the load and 3x the power). The 100 kW Induction system will therefore meet the customer's requirements.

Results/Benefits:

Induction preheating provides:

  • Faster heating cycles
  • The process is safer than the flame heating
  • Technology without pollution, clean and safe

Ultraflex Power Technologies, USA
Tel: + 1 631 467 6814
Email: sales@ultraflexpower.com
Web: www.ultraflexpower.com

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