Induction Melting

How does induction melting work?

Induction heating allows you to raise and hold the temperature of your material to its melting point without the use of flame or arc.

A non-conducting crucible holds the charge of material to be melted while the induction coil induces eddy currents in the charge material. Friction from these currents raises the material's temperature.

Benefits of Induction Melting

Melting metals with induction heating provides reliable, repeatable, non-contact, safe and energy-efficient heat, eliminating heat losses and workplace dangers experienced with flame. Since induction heats only the charge materials, the process is precise and efficient: it does not waste energy heating a chamber, nor does it pose the safety risk of open flame.

melting Application Notes

Select from our collection of melting notes, taken from years supporting our customers. Read how we helped to solve their process heating challenges.

image: Induction Melting iron powder; pucks for analysis Induction Melting iron powder; pucks for analysis

To heat a sample of iron powder for an induction melting application; the client manufactures metal powders

image: Induction Melting of Ni based alloy samples Induction Melting of Ni based alloy samples

Induction melting provides hands-free heating, involves no operator skill required for manufacturing, even distribution of heating and fast, controllable temperature ramp

image: Heating a crucible for Melting plastic Heating a crucible for Melting plastic

A single-position 6-turn helical coil is used to generate the required heating for application. The crucible is heated in 70 seconds with the 5kW power supply.

image: Induction Melting silicon in graphite crucible for material testing Induction Melting silicon in graphite crucible for material testing

The customer is developing a university lab experiment to induction melt silicon and is still developing the process.

image: Induction Melting lead ingots to form battery posts and connectors Induction Melting lead ingots to form battery posts and connectors

Induction Melting 30 lb(13.6 kg) & 60 lb(27.2 kg) lead ingots to form battery posts & connectors

image: Induction Melting the end of a plastic tube to create a seal Induction Melting the end of a plastic tube to create a seal

A single turn coil encapsulated in custom blocks is used for sealing the tube. Two tubes are placed between the coil blocks and a 7lb (3.2kg) load is applied to the top of the coil.

image: Crucible Melting a variety of materials in a nitrogen atmosphere Crucible Melting a variety of materials in a nitrogen atmosphere

The crucible is heated using an induction coil with a four turn pancake at the base that extends upward into a three turn helical coil.

image: Induction Melting aluminum in a graphite crucible for casting Induction Melting aluminum in a graphite crucible for casting

Induction melting provides hands-free heating that involves no operator skill for manufacturing, repeatable, dependable results, more efficient and cost effective then gas furnace, does not heat up the manufacturing area and increases production.

image: Hermetic sealing: SS rods & glass preforms Hermetic sealing: SS rods & glass preforms

Induction melting provides hands-free heating that involves no operator skill for manufacturing, amounts of glass are precisely controlled by the glass preforms and even flow of glass creates aesthetically pleasing bond.

image: Remove plastic coating from steel tubes Remove plastic coating from steel tubes

Induction melting is the only feasible way to remove the plastic coating, leaving it in an unpolluted form for recycling. It is a faster process

image: Releasing a Lens Grinding Fixture Bond Releasing a Lens Grinding Fixture Bond

The bonded assembly is placed (glass up) within a helical coil which circles the bonding slug. Induction heats the material to the melting point in 5-7 seconds.

image: Induction Melting Glass for Fiber Drawing Induction Melting Glass for Fiber Drawing

To heat a metal susceptor vessel to 2200°F within 25 minutes with induction for a fiberglass melting application

image: Induction Melting of Ticonium and Nobilium ingots Induction Melting of Ticonium and Nobilium ingots

Due to the small size of the ingots, RF induction melting was required to efficiently couple to the samples in order to provide the necessary power to initiate melting.

Why use induction for melting?

With induction, heat is generated directly in the metal, so there is no heat loss to the surrounding environment. It's also a versatile way to heat metal, useful in melting a wide variety of materials, including ferrous and non-ferrous metals.

What is the main benefit of induction melting?

Induction heating allows you to raise and hold the temperature of your material to its melting point without the use of flame or arc. A non-conducting crucible holds the charge of material to be melted while the induction coil induces eddy currents in the charge material, raising the temperature.

What are the melting points of some common metals?

Metal	Melting Point
Carbon Steel	1425-1540°C (2597-2800°F)
Stainless Steel	1375 – 1530°C (2500-2785°F)
Aluminum	660°C (1220°F)
Copper	1084°C (1983°F)
Brass	930°C (1710°F)

Source: Industrial Metal Supply

Induction Melting Video

10 Automotive Application Notes

We have collected these 10 popular Application Notes to help you understand the many ways induction heating can improve your precision automotive manufacturing processes.