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/