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Book Chapter
Systematic Analysis of Induction Coil Failures and Prevention
Available to PurchaseSeries: 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.
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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. 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
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Image
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
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Image
Magnetic field distribution in a multiturn induction coil showing the coil ...
Available to Purchase
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
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Magnetic field distribution in a multiturn induction coil showing the coil ...
Available to PurchasePublished: 01 November 2010
Fig. 31 Magnetic field distribution in a multiturn induction coil showing the coil end effect. Source: Ref 11
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Cross sections of typical induction billet heating coils. S, induction coil...
Available to PurchasePublished: 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
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Insulation technique for the induction coil of vacuum induction furnaces. C...
Available to Purchase
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
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Inner side of the induction coil of a vacuum induction melting (VIM) furnac...
Available to Purchase
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
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Published: 01 August 2013
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Temperature distribution in the induction coil with 1 mm (0.048 in.) wall t...
Available to Purchase
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
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Image
Temperature distribution in the induction coil with wall thicknesses of (a)...
Available to Purchase
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
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Image
Temperature distribution in the induction coil with (a) 1 mm (0.048 in.) wa...
Available to Purchase
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
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Image
Temperature distribution in the induction coil with (a) 1 mm (0.048 in.) wa...
Available to Purchase
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
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Image
Temperature distribution in the induction coil with (a) 1 mm (0.048 in.) wa...
Available to Purchase
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
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Round replaceable induction coil liners used in the design and manufacture ...
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. 21 Round replaceable induction coil liners used in the design and manufacture of induction coils
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Rectangular replaceable induction coil liners used in the design and manufa...
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. 22 Rectangular replaceable induction coil liners used in the design and manufacture of induction coils
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Image
Induction coil designed with silicon nitrite trapezoid wear rails that are ...
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. 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
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Induction coil with laminations stacked between mechanical supports. Courte...
Available to Purchase
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.
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in Magnetic Flux Controllers in Induction Heating and Melting
> Induction Heating and Heat Treatment
Published: 09 June 2014
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Comparison of integral power values for traditional induction coil design w...
Available to Purchase
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
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