Inline Induction Wire Heating

Objective
Heat several different wire diameters to 204°C (400°F) in 0.8 seconds with the same induction coil.

Equipment
UltraHeat 10kW Power Supply
HS8LF Heat Station

Test 1

Materials
• 0.110″(2.79mm) dia wire

Power:
2.22 kW

Temperature: 
204°C (400°F)

Time: 0.9 sec

Test 2

Materials
• 0.067″ (1.70mm) dia wire

Power:
5.25 kW

Temperature: 
204°C (400°F)

Time: 0.9 sec

Test 3

Materials
• 0.06″ (1.52mm) dia wire

Power:
5.25 kW

Temperature: 
204°C (400°F)

Time: 0.60 sec

Test 4

Materials
• 0.05′ (1.27mm) dia wire

Power:
3.77 kW

Temperature: 
204°C (400°F)

Time: 0.70 sec

Process Steps:

1. Clean and apply 204°C (400°F) Tempilaq over the length of the wire.
2. Apply induction heat for 0.8 seconds.

Results and Conclusions:

All wires exceeded 204°C (400°F) over full length of coil. Further development testing will be required to optimize the equipment for the application for the fastest rates available. Tuning and optimization of the equipment would need to be done with a continuous wire feed in the unit.

Based on the results, a 5kW power supply can be used, and further development testing would guarantee the desired rates. A 10kW power supply will recommended. The additional power will make the tuning and development testing easier for the end user and leave additional power for production rates to be easily increased in the future.

Pictures

Video