INDUCTION FURNACES

There are two basic types of metal-melting induction furnaces: (1) core-less and (2) core-type. Both
types utilize the principle of a transformer.
The high-voltage circuit is coupled with that of the low voltage without directly connecting the two
circuits. The element responsible for this coupling effect is the magnetic field. Induction heating
utilizes the property of the magnetic field, which enables heat to be transferred without direct contact.
By correctly disposing the high-voltage winding, which in the case of the induction furnace would be
an induction coil or inductor, the magnetic field is directed so that the metal to be heated or melted is
made to absorb energy. The temperature attainable is limited solely by the resistance to heat of the
surrounding lining material. Induction heating enables any temperature to be achieved while providing
for excellent regulation of temperature and metallurgical properties.
Any metal which will conduct electric current can be melted in an induction furnace.
Coreless Induction Furnaces (See Fig. 7.5.8.) This type of furnace consists of a crucible, copper coil,
and framework on supports arranged for tilting and pouring. The specially designed induction coil acts
as the primary of the transformer. The crucible conforms to conventional refractory practice. A
rammed crucible is used for furnaces above 50 kW, and preformed crucibles are used on smaller
furnaces such as laboratory units.
The principle of operation is essentially the same as that of the induction heater previously described.
The initial charge in the furnace is cold scrap metal — pieces of assorted dimensions and shapes and
a large percentage of voids. As the power is applied and the heat cycle progresses, the charge
changes to a body of molten metal; additional cold metal is added until the molten-metal level is
brought to the desired temperature and metallurgical chemistry. The furnace then is tapped.
When the metal in the furnace becomes fluid, depending on whether a line frequency or medium-
frequency supply by means of convectors is used, a certain electromagnetic stirring action will occur.
This stirring action is peculiar to the induction furnace and aids in the production of certain types of
alloys. The stirring action increases as the frequency is reduced.
Line-frequency applications are generally reserved to furnaces having a metal-holding capacity of 800
lb (360 kg) and above. There is always an ideal relationship between the size of a coreless furnace
and its operating frequency. As a general rule, a small furnace gives best results at high to medium
frequencies and large furnaces work best at the lower frequencies. A frequency is suited to a given
furnace when it yields good, fast melting with a gentle stirring action. Too high or too low frequencies
are accompanied by undesirable side effects. The tabulation below gives the charge weights and
frequencies generally to be used:
Charge weight, lb. Frequency, Hz
2 – 50 9,600
12 – 500 3,000
200 – 15,000 960
800 – 75,000 60

The coreless induction furnace is usually charged full and tapped empty, although at line frequencies,
it may be necessary to retain a certain amount of metal in the furnace to continue the operation, since
it is difficult to start the furnace with small metal particles, such as turnings and borings, in a cold
crucible. As a result, it is general practice to retain a heel in the furnace of about one-third its molten-
metal volume.
This problem can be avoided in furnaces of higher frequencies, where start-up can be performed with
small-size metal charges without carrying the heel.
Coreless induction furnaces are particularly attractive for melting charges and alloys of known
analysis; in essence, the operation becomes one of metal melting with rapidly absorbed electric heat
without disturbing the metallurgical properties of the initial charge.
These furnaces are supplied from a single-phase source. In order to obtain a balanced three-phase
input, it is necessary specifically to design the electrical equipment for the inclusion of capacitors and
suitable reactors, which are generally automatically switched (by inductance changes) during the
operation in order to provide a reasonably high power factor. Power factors on such furnaces can be
kept at or near unity. In high-frequency coreless induction furnaces, high power factors are necessary
to prevent overburdening the motor-generator equipment.
Core-Type Induction Furnaces (See Fig. 7.5.9.) The transformer is actually wound to conform to a
typical transformer design having an iron core and layers of wire acting as a primary circuit. The
melting channel acts as a ring short circuit around this transformer in the melting chamber. According
to the desired melting capacity, one, two, or three such transformers (or inductors, as they are called)
may be added to the furnace shell. At all times, the channel must hold sufficient metal to maintain a
short circuit around the transformer core. Air cooling is used as required to prevent undue heating of
the inductor coils and magnetic cores.

The melting output is controlled by varying the voltage supplied to the inductors with the aid of a
variable-voltage transformer connected to the primary circuit of the supply. Core-type furnaces always
use line frequencies. Voltage or power-input regulation, therefore, can be per-formed by adjusting the
tap setting of the transformer feeding the furnace transformer attached to the furnace shell. These
transformers are single-phase units, and by using three such units, a balanced three-phase input can
be obtained. The current flowing through the primary inductors by transformation causes a much
larger current in the metal loop, whose resistance creates heat for melting.
The core-type furnace is the most efficient type of induction furnace because its iron core
concentrates magnetic flux in the area of the magnetic loop, ensuring maximum power transfer from
primary to secondary. Efficiency in the use of power can be as high as 95 to 98 percent.
The essential loop of metal must always be maintained in the core-type furnace. If this loop is allowed
to freeze by cooling, extreme care is necessary in remelting because the loop may rupture and
disrupt the circuit. This could require extensive work in dismantling the coil and restoring the loop.
Consequently, core-type furnaces rarely are permit-ted to cool. This makes alloy changes difficult
because a heel of molten metal always is required.
The relatively narrow melting channels must be kept as clean as possible since a high metal
temperature exists in this loop. Nonmetallic or tramps in the charge metal tend to accumulate on the
walls in the channel area, restricting the free flow of metal and ultimately closing the passage.
This furnace is particularly useful for melting of nonferrous metals such as aluminum, copper, copper
alloys, and zinc.
POWER REQUIREMENTS FOR ELECTRIC FURNACES
The energy required for melting metals in electric furnaces varies for a given metal or alloy with the
size of the furnace, the thickness of the refractory lining, the temperature of the molten metal, the rate
of melting, and with the degree of the continuity of the operation of the furnace.
An estimated efficiency of 50 to 60 percent is often used for preliminary purposes. As is well known,
3- to 6-ton direct-arc furnaces often are used to tap acid foundry steels with the consumption of less
than 500 kWh to the ton, and large ingot furnaces of this same type, operating basic-lined on
common steels for ingots, give even better results despite the call for several more charges of scrap
per heat.
Average values in kWh / ton of molten metal are as follows: yellow brass, 200 to 350; red brass, 250
to 400; copper, 250 to 400; lead, 30 to 50; steel melting, when making high-quality double-slag basic
heats, 650 to 800 (Table 7.5.3).
Electrode consumption varies considerably in arc furnaces because of their different constructions
and operations. Average values in pounds of electrode per ton of molten metal are: steel melting, with
graphite electrodes, 5 to 10; brass melting, with graphite electrodes, 3 to 5.
Graphite electrodes have largely superseded carbon electrodes,
Table 7.5.3 Energy Consumption of Electric Furnaces