Introduction p. 1 History p. 3 Applications of Induction Heating p. 4 Preheating Prior to Metalworking p. 6 Heat Treating p. 6 Melting p.

Transcription

1 Introduction p. 1 History p. 3 Applications of Induction Heating p. 4 Preheating Prior to Metalworking p. 6 Heat Treating p. 6 Melting p. 6 Welding, Brazing, and Soldering p. 6 Curing of Organic Coatings p. 6 Adhesive Bonding 7Semiconductor Fabrication p. 7 Tin Reflow p. 7 Sintering p. 7 Advantages of Induction Heating p. 7 Theory of Induction Heating p. 9 Basis for Induction Heating p. 9 Eddy-Current Distribution in a Solid Bar p. 13 Equivalent Resistance and Efficiency--Solid Round Bar p. 16 Equivalent Resistance and Efficiency--Other Geometries p. 21 Determination of Power Requirements p. 23 Tuning of Induction Heating Circuits and Load Matching p. 27 Tuning of Induction Heating Circuits p. 28 Series Resonant Circuits p. 28 True, Reactive, and Apparent Power p. 30 Parallel Resonant Circuits p. 31 Tuning Capacitors p. 32 Transformers and Impedance Matching p. 35 Impedance Matching and Tuning for Specific Types of Power Supplies p. 38 Fixed-Frequency Sources p. 38 Variable-Frequency (Solid-State) Power Sources p. 41 Radio-Frequency (Vacuum-Tube) Power Supplies p. 42 Induction Heating Power Supplies p. 47 Frequency and Power Selection Criteria p. 47 Types of Power Supplies p. 50 Line-Frequency Induction Heating p. 50 Frequency Multipliers p. 55 Motor-Generators p. 57 Solid-State Inverters p. 63 Spark-Gap Converters p. 67 Radio-Frequency (Vacuum-Tube) Power Supplies p. 67 Radio-Frequency (Solid-State) Equipment p. 74 Auxiliary Equipment for Induction Heating p. 77 Equipment Cooling Systems p. 77

2 Water-Cooling Systems p. 79 Vapor-Coolant Systems p. 80 Timers p. 82 Process Design for Specific Applications p. 85 Design Procedures for Through Heating p. 85 Selection of Frequency for Through Heating p. 86 Selection of Power Rating for Through Heating p. 96 Design Procedures for Heat Treating p. 105 Surface Hardening p. 106 Localized Annealing of Steel Pipe Welds p. 115 Design Procedures for Induction Melting p. 118 Design Considerations for Coreless Induction Melting Furnaces p. 120 Design Considerations for Channel Induction Melting Furnaces p. 127 Design of Induction Pipe Welding Operations p. 128 Mechanical Design Features p. 128 Electrical Design Features p. 133 Design of Induction Brazing and Soldering Operations p. 135 Fundamentals of Process Control p. 143 Temperature Measurement p. 144 Thermocouples p. 144 Radiation Detectors p. 149 Other Temperature-Measuring Techniques p. 156 Temperature-Control Modes p. 163 Proportional Controllers and Heat-Regulating Devices p. 164 Integration of Control Functions p. 166 Heating of Steel Slabs p. 167 Surface Hardening p. 168 Vacuum Induction Melting p. 169 Electric-Demand Control p. 170 Distributed Control p. 170 Concept of Distributed Control p. 170 Interfacing/Connecting Control-System Components p. 173 Miscellaneous Control Technologies Used in Induction Heating p. 174 Electromagnetic Sorting p. 174 Resistivity Measurement of Case Depth p. 177 Calorimetric Evaluation of Induction Hardening p. 178 Process Simulation p. 178 Problem Formulation p. 179 Simulation of Surface Hardening p. 180 Coil Design and Fabrication p. 185 Basic Design Considerations p. 185

3 Basic Coil Designs p. 188 Low-Frequency Heating p. 188 Medium-to-High-Frequency Coils p. 189 Internal Coils p. 191 Common Design Modifications p. 193 Coil Characterization p. 193 Flux Diverters p. 201 "Balancing" of Multiplace Coils p. 203 Specialty Coils p. 205 Master Work Coils and Coil Inserts p. 206 Coils for Induction Scanners p. 209 Split Coils p. 211 Concentrator Coils p. 212 Butterfly Coils p. 216 Split-Return Inductors p. 217 Tapped Coils p. 217 Transverse-Flux Coils p. 218 Series/Parallel Coil Construction p. 220 Tuning Stubs (Trombones) p. 221 Conveyor/Channel Coils p. 223 Coil Fabrication p. 226 Selection of Tubing p. 227 Coil Forming p. 228 Joining of Coils to Power-Supply Leads p. 229 Bracing of Coils p. 231 Power-Supply Leads p. 234 Design Considerations p. 234 Typical Lead Design p. 237 Flux Concentrators, Shields, and Susceptors p. 241 Flux Concentrators p. 241 Materials for Flux Concentrators p. 242 Application of Flux Concentrators p. 244 Shields p. 244 Shield Design p. 245 Typical Applications of Shields p. 245 Susceptors p. 247 Susceptor Materials p. 248 Typical Applications of Susceptors p. 251 Materials Handling p. 253 Basic Considerations in Materials Handling p. 253 Part Movement Through Induction Coil p. 253

4 Materials for Handling Fixtures p. 255 Use of Controlled Atmospheres or Vacuum p. 257 Materials Handling in Induction Billet and Bar Heating p. 260 Feed Mechanisms p. 261 Feed-Mechanism Selection Criteria p. 264 Materials Handling in Induction Heat Treatment p. 264 Continuous Heat Treatment p. 266 Heat Treatment of Discrete Parts p. 269 Materials Handling in Induction Soldering and Brazing p. 273 Materials Handling in Other Induction Heating Processes p. 275 Robot Design p. 278 Robot Drive Mechanisms p. 279 Robot Tooling Systems and Motions p. 279 Control and Programming of Robots p. 279 Special Applications of Induction Heating p. 281 Induction Heating Applications in the Plastics and Rubber Industries p. 281 Bonding and Forming of Plastics p. 281 Plastic Coatings p. 285 Salvage Operations p. 287 Bonding Applications of Induction Heating p. 288 Induction Cap Sealing and Packaging p. 291 Induction Heating Applications in the Electronics Industry p. 292 Zone Refining of Semiconductors p. 293 Growth of Semiconductor Single Crystals p. 294 Epitaxial Deposition p. 296 Production of Silicon Solar Cells p. 298 Hermetic Sealing and Salvage of Electronic Components p. 298 Manufacture of Vacuum Tubes p. 300 Induction Heating Applications in the Glass Industry p. 301 Glass-to-Metal Sealing p. 301 Glass Melting p. 302 Lens Blocking p. 302 Fiber-Optic Manufacture p. 302 Induction Heating Applications in Steel Finishing p. 303 Tin Reflow p. 304 Paint Curing p. 305 Vessel Heating p. 306 Application of Induction Heating for Vacuum Processes p. 308 Vacuum Melting p. 309 Directional Solidification p. 310 Levitation Melting p. 310

5 Economics p. 315 Cost Elements of Induction Heating p. 315 Equipment Costs p. 315 Energy Costs p. 316 Production Lot Size and Ease of Automation p. 317 Scale and Scrap Losses p. 318 Labor Costs p. 319 Maintenance Costs p. 319 Other Cost Elements p. 320 Typical Cost Comparisons p. 320 Heating of Steel Billets Prior to Forging p. 320 Heating of Nonferrous Billets Prior to Forging/Extrusion p. 320 Heat Treating of Steel p. 321 Tube Welding p. 323 Index p. 325 Table of Contents provided by Blackwell's Book Services and R.R. Bowker. Used with permission.