World Best Induction Melting furnace

Stead Fast Induction melting Furnace are designed for maximum electrical efficiency using heavy walled, high electrically conductive copper tubing. Stead Fast Engineers manufactures world class induction melting furnaces under the brand name 'STEFEN'. STEFEN Quick melt and Smart melt furnaces are designed to increase the customer’s profitability and improve his market credibility by minimizing down time. Stead Fast furnaces are designed to provide world class induction heating and melting solutions for both ferrous and Non ferrous with a great focus on customization so that every machine is nothing less than perfect.


Stefen Box Type Induction Furnace :

• Available from 50kg to 1000kg
• Suitable for small and medium foundries for melting of ferrous and non ferrous material
• Rolled Aluminum side plates for better flux shielding
• Rigid Cradle Design
• High purity EC Grade copper coil for better efficiency
• Very easy to install, operate and maintain
• Negligible Breakdown
• High performance guarantee

    
Stefen Steel Shell Type Induction Furnace :

• Rugged and Heavy duty Steel frame provides tension free support to the coil
• Large Shunts made from CRGO imported steel provide low resistance flux path leading to higher efficiency
• Easy access to coil leading to easy maintenance
• 3D Designed and Load tested
• Optional Fume extraction system

Stefen Push-Out Furnace :

• Trouble free Operation
• For small capacity of 2kg to 50 kg
• Crucible is pushed out hydraulically in a smooth motion
• Compact system

Stead Fast Engineers has a team of skilled engineers having vast experience and technical know-how in the induction field. With a wide range of products Stead Fast has emerged a pioneer in the induction world. for more product Details Visit : http://www.steadfastengg.com/

Designing of Inductor

It is inside of the inductor that the differing attractive field required for prompting warming is produced, through the stream of substituting current.

Inductor configuration is subsequently a standout amongst the most imperative parts of the general instigation warming machine. A very much outlined inductor gives the best possible warming example to your part and amplifies the effectiveness of the actuation warming power supply, while as yet permitting simple insertion and evacuation of the part.

The inductor does not need to be formed in a helix. With the right plan, it is conceivable to warm conductive materials of any size and shape, furthermore conceivable to warm just the part of material required. It is even conceivable to warm diverse zones of the part at the same or distinctive temperatures by method for a legitimate configuration of the inductor geometry. Temperature consistency inside of your part is accomplished through right inductor plan. The best consistency can be accomplished in round parts. Because of the way of electrical current way stream, parts with sharp edges could specially warm in those zones if the best possible inductor outline is not utilized.

Coupling Efficiency

There is a corresponding relationship between the measure of current stream and separation between the inductor and part. Setting the part near the inductor builds the stream of current and the measure of heat prompted in the part. This relationship is alluded to as the coupling proficiency of the inductor.

Fundamental Construction

Inductors are regularly made of copper tubing - a great conduit of heat and electricity - with a distance across of 1/8" to 3/16"; bigger copper loop congregations are made for applications, for example, strip metal heating and pipe heating. Inductors are normally cooled by coursing water, and are frequently uniquely crafted to fit the shape and size of the part to be heated. So inductors can have single or different turns; have a helical, round or square shape; or outlined as inner (part inside inductor) or outer (part nearby inductor).

Advance Design and Manufacturing :

Stead Fast Engineers provides world class induction heating System and melting solutions for both ferrous and Non ferrous with a great focus on customization so that every machine is nothing less than perfect. With a family of more than 400 satisfied customers all over the country and abroad, Stead Fast Engineers is expanding at a rapid pace. With offices located in major cities we ensure that the service is quick and effective and breakdown time is negligible. Adopting stringent quality management systems during different stages of production - the pre-process, In-process and pre-dispatch stage we believe in manufacturing the best quality every time.

Important Factors to Consider in Induction Furnace

The efficiency of an induction heating system for a specific application depends on several factors: the characteristics of the part itself, the design of the inductor, the capacity of the power supply, and the amount of temperature change required for the application.

The Characteristics of the Part

METAL OR PLASTIC

To begin with, induction heating works straightforwardly just with conductive materials, ordinarily metals. Plastics and other non-conductive materials can frequently be heated by implication by first heating a conductive metal susceptor which exchanges heat to the non-conductive material.

Attractive OR NON-MAGNETIC

It is less demanding to heat attractive materials. Notwithstanding the heat incited by swirl streams, attractive materials likewise deliver heat through what is known as the hysteresis impact (depicted previously). This impact stops to happen at temperatures over the "Curie" point - the temperature at which an attractive material loses its attractive properties. The relative resistance of attractive materials is appraised on a "penetrability" size of 100 to 500; while non-magnetics have a porousness of 1, attractive materials can have a penetrability as high as 500.

THICK OR THIN

With conductive materials, around 85% of the heating impact happens at first glance or "skin" of the part; the heating power reduces as the separation from the surface increases.So little or meager parts by and large heat more rapidly than vast thick parts, particularly if the bigger parts should be heated completely through.

Examination has demonstrated a relationship between the frequency of the rotating current and the heating profundity of entrance: the higher the frequency, the shallower the heating in the part. Frequencies of 100 to 400 kHz deliver moderately high-vitality heat, perfect for rapidly heating little parts or the surface/skin of bigger parts. For profound, entering heat, longer heating cycles at lower frequencies of 5 to 30 kHz have been appeared to be best.

 RESISTIVITY

In the event that you utilize precisely the same procedure to heat two same size bits of steel and copper, the outcomes will be entirely distinctive. Why? Steel – alongside carbon, tin and tungsten – has high electrical resistivity. Since these metals emphatically oppose the present stream, heat develops rapidly. Low resistivity metals, for example, copper, metal and aluminum take more time to heat. Resistivity increments with temperature, so an extremely hot bit of steel will be more responsive to induction heating than a frosty piece.

Inductor Design

It is inside of the inductor that the fluctuating attractive field required for induction heating is produced through the stream of exchanging current. So inductor outline is a standout amongst the most vital parts of the general framework. A very much planned inductor gives the best possible heating example to your part and augments the productivity of the induction heating power supply, while as yet permitting simple insertion and evacuation of the part.

Power Supply Capacity

The measure of the induction power supply required for heating a specific part can be effectively ascertained. Initial, one must decide the amount of vitality should be exchanged to the work-piece. This relies on upon the mass of the material being heated, the particular heat of the material, and the ascent in temperature required. Heat misfortunes from conduction, convection and radiation ought to likewise be considered.

Level of Temperature Change Required

At last, the productivity of induction heating for particular application relies on upon the measure of temperature change required. An extensive variety of temperature changes can be accomodated; as a dependable guideline, more induction heating power is for the most part used to build the level of temperature change.

Stead Fast Engineers is a leading and good quality Induction Furnace manufacturers in India. Possibly because we believe in innovation and skilled manpower  and penchant for quality and of course because of the trust that has been placed on us by our customers, we have built up an undoubtedly long list of prestigious clientele. Visit Our Site for more details : http://www.steadfastengg.com/

Unique Technology for Induction Billet Heaters

Induction forging alludes to the utilization of an induction heater to pre-heat metals preceding distortion utilizing a press or sledge. Regularly metals are heated to somewhere around 1,100 and 1,200 °C (2,010 and 2,190 °F) to expand their flexibility and help stream in the forging bite the dust.

Induction heating is a non-contact process which utilizes the standard of electromagnetic induction to create heat in a work piece. By setting a conductive material into a solid rotating attractive field, electric current is made to stream in the material, along these lines creating Joule heating. In attractive materials, further heat is produced underneath the Curie indicate due hysteresis misfortunes. The created current is relevantly in the surface layer, the profundity of this layer being directed by the recurrence of the exchanging field and the porousness of the material.

Billet Heating :

In the induction billet heater the entire of the billet or slug is heated. Ordinarily for short billets or slugs a container or dish is utilized to consequently display the billets in line to squeeze rollers, chain driven

tractor units or at times pneumatic pushers. The billets are then determined through the loop one behind the other on water cooled rails or earthenware liners are utilized through the curl bore which decrease contact and anticipate wear. The length of the curl is an element of the required drench time, the process duration per segment and the length of the billet. In high volume extensive cross area work it is not bizarre to have 4 or 5 curls in arrangement to give 5 m (16 ft) of loop or more. 

Common place parts handled by in line billet heating:

 Little crankshafts

 Camshafts

 Pneumatic and pressure driven fittings

 Sledge heads

 Motor valves

 Single shot

shot billet heating:

For long billets, single shot heating can be utilized. This procedure uses comparable frameworks to bar end heating aside from that the entire of the billet is crashed into individual loops. Likewise with bar end heating the quantity of curls is administered by ΔT required and the warm properties of the material being heated. Run of the mill parts prepared by single shot billet heating:

 Lorry axles

 Marine camshaf

Induction Billet Heatering Systems :

Stead Fast Engineers supply a broad range of induction billet heating systems for virtually all forge heating applications. Advantages of our induction billet heaters include:

• High efficiency

• Proven Design

• Reduced customer start up time

• Forge shop proven

• Excellent customer reference list

• Advanced PLC control, power & temperature control

• Quick release connections for both power & water

• World wide customer service support

• Reliable

• Heavy Duty Construction, for toughest forging conditions

• IGBT (Insulated Gate Bi-Polar Transistor) Design

Manufactured to perfection, we are one of the excellent and leading exporters of Induction Billet Heating Machine. Due to its high efficiency, consistent performance and longer functional life, the billet heating machine is highly reckoned in the global market. We have manufactured the billet machine for efficient heating of circular or square section billets. Our offered range of billet machine is widely used for forging application. This Induction Billet Heating Machine is stringently checked on several parameters like sturdiness, construction and efficiency.

For more Information Visit Our website : http://www.steadfastengg.com/

How does Induction heating Work ?

 Introduction :

Induction heating is a precise, quick, repeatable, proficient, non-contact strategy for heating metals or some other electrically-conductive materials.

An induction heating framework comprises of an induction power supply to convert line energy to an exchanging current and conveying it to a workhead, and a work loop for creating an electromagnetic field inside of the curl. The work piece is situated in the curl such this field prompts a current in the work piece, which thusly delivers heat.

The water-cooled loop is situated around or circumscribing the work piece. It doesn't contact the work piece, and the warmth is just delivered by the actuated current transmitted through the work piece. The material used to make the work piece can be a metal, for example, copper, aluminum, steel, or metal. It can likewise be a semiconductor, for example, graphite, carbon or silicon carbide.

For heating non-conductive materials, for example, plastics or glass, induction can be utilized to warm an electrically-conductive susceptor e.g., graphite, which then passes the warmth to the non-directing material.

Induction heating discovers applications in procedures where temperatures are as low as 100ºC (212°F) and as high as 3000°C (5432°F). It is likewise utilized as a part of short heating procedures going on for not as much as a large portion of a second and in heating procedures that stretch out more than a while.

Induction heating is utilized both residential and business cooking, in a few applications, for example, warmth treating, fastening, preheating for welding, melting, therapist fitting in industry, fixing, brazing, curing, and in and in research and development.

How Does Induction Heating Work?

Induction produces an electromagnetic field in a coil to transfer energy to a work piece to be heated. When the electrical current passes along a wire, a magnetic field is produced around that wire.

Key Benefits of Induction :

 The benefits of induction are:

 Efficient and quick heating

 Accurate, repeatable heating

 Safe heating as there is no flame

 Prolonged life of fixturing due to accurate heating

 Methods of Induction Heating

Induction heating is done using two methods:

The first method is referred to as eddy current heating from the I²R losses caused from the resistivity of a work piece’s material. The second is referred to as hysteretic heating, in which energy is produced within a part by the alternating magnetic field generated by the coil modifying the component’s magnetic polarity.

Hysteretic heating occurs in a component up to the Curie temperature when the material’s magnetic permeability decreases to 1 and hysteretic heating is reduced. Eddy current heating constitutes the remaining induction heating effect.

When there is a change in the direction of electrical current (AC) the magnetic field generated fails, and is produced in the reverse direction, as the direction of the current is reversed. When a second wire is positioned in that alternating magnetic field, an alternating current is produced in the second wire.

The current transmitted through the second wire and that through the first wire are proportional to each other and also to the inverse of the square of the distance between them.

When the wire in this model is substituted with a coil, the alternating current on the coil generates an electromagnetic field and while the work piece to be heated is in the field, the work piece matches to the second wire and an alternating current is produced in the work piece. The I²R losses of the material resistivity of the work piece causes heat to be created in the work piece of the work piece’s material resistivity. This is called eddy current heating.

Working of an Induction Coil

With the assistance of a rotating electric field, vitality is transmitted to the work piece with a work coil.

The rotating current passing through the coil delivers the electromagnetic field which instigates a present going in the work piece as a mirror picture to the present going in the work coil. The work coil/inductor is a piece of the induction heating framework that shows the viability and proficiency of the work piece when it is warmed. Work coils are of various sorts running from complex to basic.

The helical injury (or solenoid) coil is an illustration of basic coil, which comprises of numerous turns of copper tube twisted around a mandrel. A coil accuracy machined from strong copper and brazed together is a sample of complex coil.

About us : 

A good induction furnace manufacturer is not just a company that makes the furnace. A good manufacturer will provide other services to assist the equipment’s purchaser into the future. If you are looking for Induction Furnace Manufacturers providers and exporters, then your search ends here.stead Fast Engineers Pvt Ltd is a one of the leading manufacturers in India where you can Get Best Induction furnace. we provide various type of heating and melting equipments . visit for more detail : http://www.steadfastengg.com/

Types of Induction Furnace

The principle of induction melting is that a high voltage electrical supply from a primary induces a low voltage, high current within the metal, or secondary. heating is just a technique of transferring heat.

Induction furnaces square measure ideal for softening and alloying a large style of metals with minimum melt losses, however, very little purification of the metal is feasible.

There are two main types of induction furnace : 

1. Coreless 

2. Channel

Coreless Induction Furnaces : 

The heart of the coreless induction furnace is that the coil, that consists of a hollow section of significant duty, high physical phenomenon copper tube that is wound into a turbinate coil. Coil form is contained inside a steel shell and magnetic shielding is employed to forestall heating of the supporting shell. to safeguard it from warming, the coil is cool, the water bing recirculated and cooled during a cooling. The shell is supported on trunnions on that the furnace tils to facilitate running.

The vessel is created by ramming a granular refractory between the coil and a hollow internal former that is liquified away with the primary heat feat a mold lining.

The power cubmicle converts the voltage and frequency of main offer, ot that needed for electrical melting. Frequencies utilized in induction melting vary from fifty cycles per second (mains frequency) to ten,000 cycles per second (high frequency). the upper the operational frequency, the bigger the most quantity of power which will be applied to a chamber of given capability and also the lower the quantity of turbulence elicited.

When the charge material is liquified, the interaction of the magnetic flux and also the electrical currents flowing within the coil manufacture a stirring action inside the liquified metal. This stirring action forces the liquified metal to rise upwards within the centre inflicting the characteristic gristle on the surface of the metal. The degree of stirring action is influenced by the ability and frequency applied further because the size and form of the coil and also the density and viscousness of the liquified metal. The stirring action inside the tub is vital because it helps with combination of alloys and melting of turnings further as homogenising of temperature throughout the chamber. Excessive stirring will increase gas obtain, lining wear and oxidisation of alloys.

The coreless induction chamber has for the most part replaced the vessel chamber, particularly for melting of high temperature alloys. The coreless induction chamber is often wont to soften all grades of steels and irons further as several non-ferrous alloys. The chamber smart} for remelting and alloying attributable to the high degree of management over temperature and chemistry whereas the induction current provides good circulation of the soften.

Channel Induction Furnaces :

The channel induction chamber consists of a refractory lined steel shell that contains the liquified metal. connected to the steel shell and connected by a throat is an induction unit that forms the melting part of the chamber. The induction unit consists of AN iron core within the variety of a hoop around that a primary coil is wound. This assembly forms an easy electrical device within which the liquified metal loops includes the secondary part. the warmth generated inside the loop causes the metal to flow into into the most well of the chamber. The circulation of the liquified metal effects a helpful stirring action within the soften.

Channel induction furnaces square measure usually used for melting low temperature alloys and or as a holding and superheating unit for higher temperature alloys like forged iron. Channel induction furnaces are often used as holders for metal molten off peak in coreless induction induction units thereby reducing total melting prices by avoiding peak demand charges.

Stead Fast Engineers provide world class induction heating and melting solutions .Stead Fast Engineers manufactures world class induction melting furnaces under the brand name 'STEFEN'. 

STEFEN Quick melt and Smart melt furnaces are designed to increase the customer’s profitability and improve his market credibility by minimizing down time.

visit products and services : http://www.steadfastengg.com/induction-melting-solutions.php

Introduction to Modern concept of Steel Making through Induction Furnaces

l . Introduction

The different sorts of Induction Furnaces utilized for Steel making are medium frequency and high frequency. Gentle steel, Stainless Steel and low and high combination Steel can be produced using this furnaces. Crude materials utilized are Steel dissolving Scrap and Direct Reduced Iron. Alloying components included according to prerequisite.

2. Brief history of making steel by Induction Furnaces course

2.1 In India we began utilizing Mains Frequency Induction Furnaces from mid?sixties and medium frequency imported induction furnaces from mid-seventies however a sudden development occurred from mid eighties upto mid?nineties when indigenous production of Induction Furnaces initiated. At first we were utilizing them for using so as to dissolve and making Stainless steels imported stainless steel scrap yet economic situation from mid-eighties urged business people to make gentle steel. On the other hand, after liberalization there was extensive increment in the quantity of induction furnaces furthermore limit per charge. Presently a-days, furnaces upto a most extreme of 16-ton/charge are being utilized.

3. Current status of Induction Furnaces

3.1 Modernisation has been did by utilizing refining, hardware and in addition ceaseless casting of billets. To make great nature of gentle steel, refining by utilizing (LRF) scoop refining furnaces are being used and for production of stainless steel, AOD refining vessels are utilized. It is fitting to utilize family synthetic sythesis medium and substantial steel softening scrap. Preceding creation of Direct Reduced Iron (DRI), it was hard to control science of melt however now the innovation of utilizing DRI to modify science has been comprehended. Carbon would he be able to balanced according to particular and tramp components are controlled in light of the fact that DRI does not have tramp metals and components.

4. Why steel in India is produced using I.F. course ?

4.1 India is the first nation utilizing Induction Melting Furnaces for making mellow steel. In actuality, EAFs are not making mellow steel of basic quality for over 10 years now. The heft of basic quality mellow steel for long items is made by Induction Melting Furnaces. Amid 2001?2002 period more than 4.5 million tons of steel were created by Induction Furnaces. The EAF units have likewise introduced Induction Melting Furnaces. There are a few explanations behind the fame of Induction Melting Furnaces for making steel. They expend less power contrasting EAFs. Consumption on terminal is nil. They utilize lesser amount of stubborn. Introductory speculation is less on plant and hardware. Accordingly, there are financial points of interest in making steel through Induction Furnaces course. The main tangle is that at present mass amount steel can't be delivered through Induction Furnace course. May be that in future it might be conceivable to do as such.

5. Smaller than normal coordinated steel plant idea

5.1 another pattern of making steel in India is developing. This new innovation is utilizing Direct Reduced Iron (DRl) - Induction Melting Furnaces (vast limit) Continuous Casting of Billets or Rolling Mills to Make Billets and Bars, Fods and Sections.

5.2. At first M/s Essar Gujarat introduced DRI unit and utilized EAF (150 tons) to make steel for level items. Some all the more such steel plants have been introduced. Some unmistakable DRI makers have likewise introduced Induction Melting Furnaces to make gentle steel ingots or billets. Amid the last a few years numerous DRI making plants have been introduced in States like Chattisgarh (cut Out of Madhya Pradesh), Jharkhand (cut out of Bihar), Orissa and West Bengal differing from 20,000 tons upwards. These states are rich in Iron metal and coal. Amid DRI making from coal, waste gasses turning out are rich in carbon monoxide/dioxide, Methane?Ethane, and so on., and henceforth have parcel of calorific qualities to produce influence taking and by amount of influence from State Electricity Boards and utilizing its own particular created influence, DRI plants are introducing different limit Induction Furnaces. Some have likewise descending manufacturing units like concast or moving factories. Accordingly a kind of Mini Integrated Steel Plants are coming up. This innovation is quick getting to be well known and may alter our old and set up idea of making steel. The mellow steel delivered by such plants is modest and of good duality. Notwithstanding, much will rely on economies of generation and business sector strengths. Numerous, different advances are coming up which all have introduction to nearby conditions and assets accessibility. Induction Furnaces industry needs to confront numerous difficulties in this period of rising new innovations for making steel.

6. Different sorts of steel and cast iron creation by I.F.

6.1 Mild Steels: with a specific end goal to control science of finished item, compound investigation of all info metallic is taken before winding the charge-blend. After half charging is finished a shower test is
sent to research facility. The synthetic examination is analyzed, computations made tin further augmentations are made of info metallics. On the off chance that it has high carbon, Sulfur and phosphorous, rate Sponge iron in the charge is expanded. At the point when 80% softening is finished a last shower test is taken. In the event that carbon is still high a greater amount of wipe iron fines are charged in the event that carbon is less, cast iron scrap and turnings are charged. Along these lines, the science is controlled. Since no
overwhelming arcing like Electric Arc Furnace:; happens in Induction Melting Furnaces, the oxidation of iron a great deal less and misfortunes are likewise insignificant. Silicon a Manganese in metal are oxidized by FE2 O3 and FeO Carbon is lessened by iron oxide of DRI. Sulfur and phosphorous are weakened by DRI. There are no cable car components in the last item.

6.2 Low Alloy Steels :
6.2.1 At present Low composite steels are by and large frequently created by Induction Furnace Units in India. The incorporate EN18, EN19, EN8, EN9, and so on. Compound arrangement is entirely controlled by utilizing spectrometer. Size of ingots differs 3½ x 4½ to as much
6 ½" x 7½". So far none of the Induction Furnaces units have delivered these steels by concast prepare however some Induction Furnaces units are introducing spoon refining and concast gear to make concast billets.

6.3 Stainless Steels :
6.3.1 Induction Melting Furnaces before making Mild Steel ingots began creating Stainless Steel subsequent to 1979?80 period utilizing little size Induction Furnaces. The crude material was foreign made SS scrap and purging so as to cast ingots fluid metal in spoon, including alloying components and so on and softening mellow steel scrap and including ferro?allow and exchanging the fluid metal to AOD vessels for refining. After AOD treatment a few units do further refining in LRF and afterward creating billet by concast process. All units having scoop refining framework have introduced spectrometer for exact and faster shower investigation. Gas levels such N2H2 and O are additionally dictated by the recently introduced instruments. The greater part of the Induction Furnaces units are creating utensils grade SS. Two Induction Furnaces units making SS have sent out bars and wires. More butt-centric more Induction Furnace units are modernizing and also expanding to esteem included items.

6.4 Grinding Media :

6.4.1 Five Induction Furnace units are creating Grinding Media MnCr5, 20 MnCr5, and so forth situated at Ghaziabad. Jhansi, Ahmedabad and Bangalore. what's more, trading. It meets the quality prerequisites of world standard.

6.5 Special Cast Iron and S.G. Iron castings:
6.5.1 While numerous cast iron casting foundries have introduced mains frequency Induction Furnaces to make exceptional cast presses, some have introduced medium frequency Induction furnaces to make
S.G. iron. These foundries have compound testing, sand testing and physical testing gear alongside ultrasonic testing supplies. It is learnt that these Induction Furnace units have traded unique Cast iron and SG iron worth crores of rupees throughout the years.

7. Conclusion

7.1 Steel making procedure is tinder going extensive changes, New procedures are being created to utilize different sorts of Iron metals, coal and gas. Iron metal fines are utilized for making Pig Iron. These are produced by European Countries, In India National Mineral Development Corporation have a concurrence with Russia to receive Romalt process by utilizing fines of Iron metals. Ideally the generation will start without further ado. Jindal's have bought an innovation called Corex process. Steel has been delivered effectively by Jindal's. It is to be seen whether new procedures are econornicaly feasible contrasting with old frameworks i.e. Coke over, Blast furnaces, steel making by BOF converters' M/s Usha Martin organization are making pig iron in cupela and it is charged hot in Electric Arc Furnace to mak steel. Every one of these procedures trim to make less expensive steel and discussion of vitality. Duplexing and Tripplexing procedure is may get to be important to make steel in future.

About Stead Fast Engineers Pvt Ltd :

Established in 1990, Stead Fast Engineers Pvt Ltd is an engineering company engaged in designing and manufacturing of Induction Melting furnaces, Induction Billet Heaters and Refractory Lining Machines for Foundries, Steel Plants and Forging units. With the help of years of experience and a highly skilled team, we create products with attention to every minute detail thereby making the products both user friendly and economical.  http://www.steadfastengg.com/

MAGNETIC HEATING OF BILLETS

INTRODUCTION

In July 2008 the new innovation – magnetic billet heater – was put into business operation in Germany (German aluminum expulsion works Weserlau GmbH and Co. KG). The second framework has been requested by Italian backup of Sapa in Bolzano. The beginnings of this innovation can be found in 2004. Organizations Zenergy Power and Bültmann got financing from Germany's ecological financing organization DBU to add to another innovation for billet heating. The main model was appeared in April 2005 at the Hannover Fair. Further with the support from the DBU, the gadget was produced and put into administration at Wese

HISTORY AND ADVANTAGES OF MAGNETIC HEATING :

In July 2008 the new innovation – magnetic billet heater – was put into business operation in Germany (German aluminum expulsion works Weserlau GmbH and Co. KG). The second framework has been requested by Italian backup of Sapa in Bolzano. The beginnings of this innovation can be found in 2004. Organizations Zenergy Power and Bültmann got financing from Germany's ecological financing organization DBU to add to another innovation for billet heating. The main model was appeared in April 2005 at the Hannover Fair. Further with the support from the DBU, the gadget was produced and put into administration at Wese.

CONVENTIONAL INDUCTION HEATING (AC HEATING) :

Electrically conductive materials are today heated or dissolved in routine incitement heating gadgets. Billet is put inside copper curl. The curl is supplied by AC current and creates electromagnetic field that alters course in time. The field affects vortex currents in the workpiece (Faraday's law) what's more, vortex currents heat up the billet because of its electrical resistivity (Joule's law). In both parts of the gadget (inductor loop, workpiece) electrical misfortunes happens. The heating of the curl is the principle wellspring of vitality misfortunes in traditional AC incitement heating frameworks. Thus, loop must be cooled with water to keep from softening. The degree of the misfortunes relies on upon the proportion of the resistances of the loop and the billet. The proficiency of the framework is 50 – 60%. Traditional gadgets have a few impediments. Air conditioning heaters working with basic force network frequencies create whirlpool currents for the most part near to the surface of the workpiece – it delays the time of heating. AC induction heating further requires a medium voltage power supply and VAR compensation.

DC MAGNETIC HEATING :

Magnetic heater in Weserlau comprises of DC fueled superconductive magnetic curl cooled to low temperature. The loop produces an adequately solid magnetic field with a force information of 10W.

Magnetic field of a DC fueled curl is not fluctuating in time, the billet is pivoted inside of the field in request to affect vortex currents. Vortex currents work to contradict the revolution and make an in number braking  torque. This is overcome by mechanical electric engines of a size of 100 – 50 kW. Engines are supplied by standard recurrence converters (misfortunes 2-3% of the aggregate influence utilization of the heater). Cooling framework and power supply devour around 13 kW, the aggregate productivity (counting all misfortunes brought on by fringe specialized gadgets) is more prominent than 80%. The heating procedure is speedier, more homogeneous Furthermore, exactly controllable. The framework doesn't require expansive cooling establishments, complex vitality supply and VAR pay. The heater comprises of four fundamental parts – superconducting magnet, refridgerator, engine and heating chamber. The fundamental part is the superconducting magnet that is kept at its working temperature by the refridgeration framework. The billets pivot in two thermally protected heating chambers, the rotational vitality is given by electric engines on either side. The engines can slide in also, out to oblige diverse billet lengths. No segment in the heater is subjected to noteworthy temperature expand, vibrations or some other mechanical anxiety compone

MAGNETIC HEATING ADVANTAGES:

• Low frequencies
• Wide material range
• Temperature tapers
• Low maintenance requirements
• Reliabilit

Stead Fast Engineers provides world class induction heating and melting solutions for both ferrous and Non ferrous with a great focus on customization so that every machine is nothing less than perfect. With a family of more than 400 satisfied customers all over the country and abroad, Stead Fast Engineers is expanding at a rapid pace. With offices located in major cities we ensure that the service is quick and effective and breakdown time is negligible. Adopting stringent quality management systems during different stages of production - the pre-process, In-process and pre-dispatch stage we believe in manufacturing the best quality every time. http://www.steadfastengg.com/

INTRODUCTION AND PRINCIPLE OF INDUCTION FURNACE

The electric induction furnace is a kind of melting furnace that uses electric streams to liquefy metal. Induction furnace are perfect for liquefying and alloying a wide assortment of metals with least soften misfortunes, be that as it may, small refining of the metal is conceivable.
The principle of induction heating is mainly based on two phenomena:
1. Electromagnetic induction
2. The Joule effect

1) ELECTROMAGNETIC INDUCTION :
The transfer of energy to the object to be heated occurs by method of electromagnetic induction. ​Any electrically conductive material put in a variable attractive field is the site of induced electric current.

2) JOULE HEATING :
​Joule heating, also known as ohmic heating and resistive heating, is the process by which the passage of an electric current through a conductor releases heat. The heat produced is proportional to the square of the current multiplied by the electrical resistance of the wire. ​

Star Point : 
Induction heating depends on the one of a kind qualities of radio frequency (RF)energy that divide of the electromagnetic range underneath infrared and microwave energy. 
Since heat is exchanged to the item by means of electromagnetic waves, the part never 
comes into direct contact with any fire, the inductor itself does not get hot and there is no item tainting. Induction heating is a quick, clean, non-contaminating heating. 
The induction coil is cool to the touch; the heat that develops in the coil is always 
cooled with flowing water.

Stead Fast Engineers Pvt Ltd is an engineering company engaged in designing and manufacturing of Induction Melting furnaces, Induction Heater and Lining Machines for Foundries Steel Plants and Forging Plants. http://www.steadfastengg.com/