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Book Chapter

Systematic Analysis of Induction Coil Failures and Prevention

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By Valery Rudnev
Series: ASM Handbook
Volume: 4C
Publisher: ASM International
Published: 09 June 2014
DOI: 10.31399/asm.hb.v04c.a0005842
EISBN: 978-1-62708-167-2
... Abstract This article focuses on the frequently encountered causes of induction coil failures and typical failure modes in fabrication of hardening inductors, tooth-by-tooth gear-hardening inductors, clamshell inductors, contactless inductors, split-return inductors, butterfly inductors...
Abstract
This article focuses on the frequently encountered causes of induction coil failures and typical failure modes in fabrication of hardening inductors, tooth-by-tooth gear-hardening inductors, clamshell inductors, contactless inductors, split-return inductors, butterfly inductors, and inductors for heating internal surfaces. It discusses the current density distribution and the skin effect, the proximity effect, and crack-propagation specifics. The article also describes selected properties of copper alloys, the electromagnetic edge effect of coil copper turn, and the effect of magnetic flux concentrators on coil life. It also reviews the importance of having appropriate and reliable electrical contacts.
View PDF for content titled, Systematic Analysis of <span class="search-highlight">Induction</span> <span class="search-highlight">Coil</span> Failures and Prevention
Image

Low-frequency coil design in which the induction coil winding is compressed...

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in Design and Fabrication of Induction Coils for Heating Bars, Billets, and Slabs > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 12 Low-frequency coil design in which the induction coil winding is compressed between end plates using long rods with threads and nuts. Courtesy of Ajax Tocco Magnethermic More
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Low-frequency coil design in which the induction coil winding is compressed...

Available to Purchase
in Design and Fabrication of Induction Coils for Heating Bars, Billets, and Slabs > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 13 Low-frequency coil design in which the induction coil winding is compressed between end plates More
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Magnetic field distribution in a multiturn induction coil showing the coil ...

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in Systematic Analysis of Induction Coil Failures and Prevention > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 26 Magnetic field distribution in a multiturn induction coil showing the coil end effect. Source: Ref 26 More
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Magnetic field distribution in a multiturn induction coil showing the coil ...

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in Simulation of Induction Heating Prior to Hot Working and Coating > Metals Process Simulation
Published: 01 November 2010
Fig. 31 Magnetic field distribution in a multiturn induction coil showing the coil end effect. Source: Ref 11 More
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Cross sections of typical induction billet heating coils. S, induction coil...

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in Induction Heating of Billets, Rods, and Bars > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 5 Cross sections of typical induction billet heating coils. S, induction coil; R, refractory insulation; G, guide rail. Source: Ref 5 , 6 More
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Insulation technique for the induction coil of vacuum induction furnaces. C...

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in Components, Design, and Operation of Vacuum Induction Crucible Furnaces > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 5 Insulation technique for the induction coil of vacuum induction furnaces. Courtesy of ALD Vacuum Technologies GmbH More
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Inner side of the induction coil of a vacuum induction melting (VIM) furnac...

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in Components, Design, and Operation of Vacuum Induction Crucible Furnaces > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 6 Inner side of the induction coil of a vacuum induction melting (VIM) furnace. Courtesy of ALD Vacuum Technologies GmbH More
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Induction coil with an offset used to provide heating uniformity

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in Induction Surface Hardening of Steels[1] > Steel Heat Treating Fundamentals and Processes
Published: 01 August 2013
Fig. 3 Induction coil with an offset used to provide heating uniformity More
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Temperature distribution in the induction coil with 1 mm (0.048 in.) wall t...

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in Design and Fabrication of Inductors for Induction Heat Treating > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 27 Temperature distribution in the induction coil with 1 mm (0.048 in.) wall thickness, 10 kHz frequency, 5000 A current, and low-pressure cooling More
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Temperature distribution in the induction coil with wall thicknesses of (a)...

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in Design and Fabrication of Inductors for Induction Heat Treating > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 29 Temperature distribution in the induction coil with wall thicknesses of (a) 1 mm (0.048 in.), (b) 1.5 mm (0.062 in.), and (c) 3 mm (0.125 in.) with 10 kHz frequency, 5000 A current, and high-pressure cooling More
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Temperature distribution in the induction coil with (a) 1 mm (0.048 in.) wa...

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in Design and Fabrication of Inductors for Induction Heat Treating > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 30 Temperature distribution in the induction coil with (a) 1 mm (0.048 in.) wall thickness, 10 kHz frequency, 7500 A current, and low-pressure cooling; (b) 1 mm (0.048 in.) wall thickness, 10 kHz frequency, 7500 A current, and high-pressure cooling; (c) 1.5 mm (0.062 in.) wall thickness More
Image

Temperature distribution in the induction coil with (a) 1 mm (0.048 in.) wa...

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in Design and Fabrication of Inductors for Induction Heat Treating > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 31 Temperature distribution in the induction coil with (a) 1 mm (0.048 in.) wall thickness, 3 kHz frequency, 7500 A current, and low-pressure cooling; (b) 1 mm (0.048 in.) wall thickness, 3 kHz frequency, 7500 A current, and high-pressure cooling; (c) 1.5 mm (0.062 in.) wall thickness, 3 More
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Temperature distribution in the induction coil with (a) 1 mm (0.048 in.) wa...

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in Design and Fabrication of Inductors for Induction Heat Treating > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 32 Temperature distribution in the induction coil with (a) 1 mm (0.048 in.) wall thickness, 1 kHz frequency, 10,000 A current, and low-pressure cooling; (b) 1 mm (0.048 in.) wall thickness, 1 kHz frequency, 10,000 A current, and high-pressure cooling; (c) 1.5 mm (0.062 in.) wall thickness More
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Round replaceable induction coil liners used in the design and manufacture ...

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in Design and Fabrication of Induction Coils for Heating Bars, Billets, and Slabs > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 21 Round replaceable induction coil liners used in the design and manufacture of induction coils More
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Rectangular replaceable induction coil liners used in the design and manufa...

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in Design and Fabrication of Induction Coils for Heating Bars, Billets, and Slabs > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 22 Rectangular replaceable induction coil liners used in the design and manufacture of induction coils More
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Induction coil designed with silicon nitrite trapezoid wear rails that are ...

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in Design and Fabrication of Induction Coils for Heating Bars, Billets, and Slabs > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 29 Induction coil designed with silicon nitrite trapezoid wear rails that are embedded into the surface of the refractory, with approximately 1.6 mm ( 1 16 in.) raised above the surface. The rails are used in both the entrance and exit ends as well as across the center More
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Induction coil with laminations stacked between mechanical supports. Courte...

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in Magnetic Flux Controllers in Induction Heating and Melting > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 3 Induction coil with laminations stacked between mechanical supports. Courtesy of Tucker Induction. More
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Induction coil with soft magnetic composites. Source: Ref 3

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in Magnetic Flux Controllers in Induction Heating and Melting > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 4 Induction coil with soft magnetic composites. Source: Ref 3 More
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Comparison of integral power values for traditional induction coil design w...

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in Magnetic Flux Controllers in Induction Heating and Melting > Induction Heating and Heat Treatment
Published: 09 June 2014
Fig. 17 Comparison of integral power values for traditional induction coil design with laminate shunts and a Fluxtrol-designed coil with soft-magnetic composite controller with top and bottom shunts. Source: Ref 14 More