Electromagnetic Induction Heating Research Articles

Biofilm on total joint replacement materials can be reduced through electromagnetic induction heating using a portable device

BackgroundPeriprosthetic joint infection is a serious complication following joint replacement. The development of bacterial biofilms bestows antibiotic resistance and restricts treatment via implant retention surgery. Electromagnetic induction heating is a novel technique for antibacterial treatment of metallic surfaces that has demonstrated in-vitro efficacy. Previous studies have always employed stationary, non-portable devices. This study aims to assess the in-vitro efficacy of induction-heating disinfection of metallic surfaces using a new Portable Disinfection System based on Induction Heating.MethodsMature biofilms of three bacterial species: S. epidermidis ATCC 35,984, S. aureus ATCC 25,923, E. coli ATCC 25,922, were grown on 18 × 2 mm cylindrical coupons of Titanium-Aluminium-Vanadium (Ti6Al4V) or Cobalt-chromium-molybdenum (CoCrMo) alloys. Study intervention was induction-heating of the coupon surface up to 70ºC for 210s, performed using the Portable Disinfection System (PDSIH). Temperature was monitored using thermographic imaging. For each bacterial strain and each metallic alloy, experiments and controls were conducted in triplicate. Bacterial load was quantified through scraping and drop plate techniques. Data were evaluated using non-parametric Mann-Whitney U test for 2 group comparison. Statistical significance was fixed at p ≤ 0.05.ResultsAll bacterial strains showed a statistically significant reduction of CFU per surface area in both materials. Bacterial load reduction amounted to 0.507 and 0.602 Log10 CFU/mL for S. aureus on Ti6Al4V and CoCrMo respectively, 5.937 and 3.500 Log10 CFU/mL for E. coli, and 1.222 and 0.372 Log10 CFU/mL for S. epidermidis.ConclusionsElectromagnetic induction heating using PDSIH is efficacious to reduce mature biofilms of S aureus, E coli and S epidermidis growing on metallic surfaces of Ti6Al4V and CoCrMo alloys.

An analysis of temperature control for electromagnetic induction heating of CFRP based on sparrow search algorithm

Accurate temperature control during the induction heating process of carbon fiber reinforced polymer (CFRP) is crucial for the curing effect of the material. This paper first builds a finite element model of induction heating, which combines the actual fiber structure and resin matrix, and systematically analyzes the heating mechanism and temperature field distribution of CFRP during the heating process. Based on the temperature distribution and variation observed in the material heating process, a PID control method optimized by sparrow search algorithm is proposed, which effectively reduces the temperature overshoot and improves the response speed. The experiment verifies the effectiveness of the algorithm in controlling the temperature of CFRP plate during the induction heating process. This study provides an effective control strategy and research method to improve the accuracy of temperature control in the induction heating process of CFRP, which helps to improve the results in this field.

Electromagnetic–thermal–mass transport triple hybrid model for energy-efficient hydrogen release from metal particles by induction heating

Hydrogen storage in metals is anticipated to be a highly promising technical approach for managing hydrogen in diverse energy applications, emphasizing the need to establish efficient operating conditions. In this study, we developed a numerical model that can simultaneously calculate hydrogen and heat transport combined with electromagnetic induction heating of metal particles. Using the developed numerical simulator, we investigated the behavior of the hydrogen release process from the hydrogen-absorbing metal and proposed important indicators for the operation. The fractions of the electromagnetic energy absorbed by the metal particle used for the hydrogen release, sensible heat, interfacial heat conduction, and thermal radiation were systematically evaluated. Considering the trade-off between temperature rise and the hydrogen concentration gradient, an optimal diameter of metal particles existed for the maximum hydrogen release rate. Similarly, the trade-off between temperature rise and energy consumption revealed an optimal electromagnetic power density for the heat utilization fraction for hydrogen release. Our electromagnetic–thermal–mass transport triple hybrid model constitutes a useful numerical simulator for the design of energy-efficient hydrogen storage systems.

Enhancement of laser ablation via high-frequency electromagnetic induction heating

The efficiency of pulsed laser ablation has always been the focus point of research. A novel high-frequency electromagnetic induction heating-assisted laser ablation scheme is proposed and investigated to enhance the efficiency and improve the surface processing quality during the nanosecond laser ablation of metal substrates. To reduce laser energy required to reach the ablation threshold of metal, this method utilizes the electromagnetic induction to rapidly elevate substrate temperature, making the metal easier to be ablated. The results show that ablation width increases 16% and ablation depth increases 31% with the assistance of electromagnetic induction heating at a laser fluence of 1.32 J/cm2, which increases 90% of the laser-ablated volume. Meanwhile, the surface ablation quality is significantly improved due to the smaller temperature gradient around the ablation region. This new method has great potentials in the laser micromachining at a higher processing efficiency and better laser-processed surface quality.

Effect of aging level on the healing properties of an induction-heated ultra-thin wearing course and its mechanism

Electromagnetic induction heating can accelerate crack self-healing in asphalt concrete and extend its service life. In the maintenance project of existing pavements, induction heating and ultra-thin wearing course can be combined by paving functional induction heating wearing course. However, the ultra-thin wearing course is directly affected by the environment and loading, and undergoes aging in the service process. Thermo-oxidative aging is an irreversible and important mechanism that seriously affect the rheological and healing properties of asphalt. Therefore, the purpose of this work is to examine the impact of thermo-oxidative aging on the induction heating-healing of an ultra-thin wearing course mixture. Firstly, the AC-5 induction heated ultra-thin wearing course (IHUC) containing 1 % steel wool fiber by aggregate mass was prepared. Subsequently, the IHUC was aged to six different levels. Then, the induction heating and healing properties of the aged IHUC were evaluated. Simultaneously, the aged asphalt binder was extracted and its rheological characteristics and chemical alterations were studied. The outcomes showed that the heating rate of IHUC decreased, but the temperature gradient effect reduced at higher aging level. The optimal healing temperature of IHUC shifted to a higher temperature region and the healing rate decreased. Both heating cycles and thermo-oxidative aging reduce healing effectiveness, but the impact of heating cycles is less compared to aging. Rheology and chemical structure test results of extracted asphalt binder showed that the transformation of the molecular structure caused the fluidity and self-healing properties of asphalt were decreased. This ultimately decreased the healing rate of IHUC.

Enhancing the catalytic H2 production performance of magnetic Ni-Fe2O3-C catalyst in biomass steam gasification using electromagnetic induction heating

In this study, a novel magnetic Ni-Fe2O3-C catalyst combined with electromagnetic induction heating in bioamass steam gasification was proposed to enhance H2 production. Better catalytic performance for H2 production was observed with the Ni-Fe2O3-C catalyst under induction heating, resulting in an increase in H2 yield from 735.1 to 2271.2 mL/g-biomass (a 209.1 % enhancement). SEM, TGA and XRD analysis demonstrated a significant decrease in coking deposition, caking, and particle agglomeration of the Ni-Fe2O3-C catalyst under induction heating, while maintaining more active sites. Importantly, the benefits of induction heating were also applicable to different magnetic catalysts like Ni-Al2O3-C, Ni-ZrO2-C, and Ni-MgO-C. Experimental results revealed a logarithmic correlation between the increase in H2 yields due to induction heating and the magnetic saturation (Ms) of the catalysts. The Ni-Fe2O3-C catalyst, with a high Ms of 50.9 emu/g, showed the highest catalytic activity for H2 production under induction heating in this study.

Performance improvement of metal hydride hydrogen compressors using electromagnetic induction heating

While there are some hydrogen refueling stations (HRS) functioning in different parts of the world, their use is not widespread enough, primarily due to their expensive cost. Hydrogen compression is a main contributor to the capital and operation costs of the HRS. By improving H2 compression technology, it is possible to optimize the infrastructure for refueling with hydrogen in terms of cost and performance. The use of metal hydride hydrogen compressors (MHHCs), which have the potential to be inexpensive and have the ability to use waste heat and renewable energy sources for the H2 compression, is a promising solution to overcome this issue. The duration of the H2 compression cycle is nevertheless a serious challenge due to the metal hydride (MH) bed's low heat conductivity. As a heating technique to improve the performance of MHHCs, electromagnetic induction (EMI) is examined numerically for the first time in this work. The dynamic behavior of a two-stage MHHC with each MH reactor having an external heat exchanger and being ringed by a copper coil traversed by an alternating current is described by a two-dimensional mathematical model, which was established and successfully verified by the reference data. Numerical simulations were performed with the help of this model, and the findings showed that the EMI heating method is faster than the heat transfer fluid (HTF) heating technique. For instance, at a delivery temperature of 373 K and a supply pressure of 20 bar, it is possible to produce 106 NL H2 per kilogram of HPMH at a pressure of 97 bar with a 74 % shorter compression time than with the HTF heating technique.

Experimental study on preheating and salt circulation performance of a single receiver tube based on induction heating

The design of a light source for a molten salt receiver experimental system has become challenging owing to the complex heating characteristics of the half-circumference surface during operation. Electromagnetic induction heating is an innovative technology that can replicate a half-circle heating scenario. However, its feasibility must be verified. In this study, we constructed a single receiver tube experimental system using induction heaters and developed a 3D numerical model coupling electromagnetic field to analyze the tube temperature distribution and molten salt temperature rise during preheating and salt circulation, considering various parameters. The results indicated that the numerical simulation agreed well with the experimental results, and the induction heater successfully reproduced the half circumference heating scenario. During preheating, a lower heat flux and higher wind speed result in a more uniform temperature distribution along the circumference of the tube wall, facilitating comprehensive preheating. During salt circulation, the heat flux and inlet salt mass flow significantly affected the temperature of the tube wall but had a relatively small effect on the back-side wall. Wind speed had the opposite effect, which was related to the arrangement of the experimental site. A higher heat flux, lower wind speed, and higher inlet salt mass flow led to a higher temperature increase in the molten salt.

A new approach for improving the quality of the carbon anode for aluminum electrolysis – An impregnation-baking process

Prebaked carbon anode is the primary consumable material in the aluminum reduction cell, and its quality directly affects the energy consumption of aluminum production. An impregnation-baking process of the anode was proposed to reduce the anode porosity, improve the quality of the anodes, and reduce additional carbon consumption. The theoretical analysis and industrial testing on the impregnation-baking process were carried out. Firstly, the coal tar pitch was immersed into the anode carbon block through the impregnation process. An anode impregnation model was developed and used for theoretical calculations to analyze the effects of pressure and temperature on the impregnation process. The accuracy of the model was verified experimentally. Secondly, the impregnated anodes were placed in an electromagnetic induction heating furnace for baking to carbonize the immersed pitch. The thermogravimetric and pyrolysis kinetics methods were used to analyze the baking process of the impregnated anodes. Finally, the impregnated-baked anodes were compared with common anodes regarding their impact on the technical and economic indicators of the aluminum electrolysis process in industrial tests. The results showed that the physicochemical properties of the impregnated-baked anodes were significantly improved, with the bulk density increase of 0.1 g/cm3, air permeability reduction of 0.54 nPm, compressive strength enhancement of 9.43 MPa, and electrical resistivity decrease of 10 uΩ·m. The anode service life was increased from 31 to 35 days, the current efficiency was increased by 0.44 %, and the operating voltage was reduced by 17 mV, which improved economic benefit significantly.

Research on the heating effect evaluation of the electromagnetic induction heating system at low temperature based on the electrochemical-thermal coupling model

The extremely fast electromagnetic induction heating system (EIHS) was recently introduced to improve the poor charge and discharge performance of lithium-ion batteries (LiBs) at low temperature. In this work, aimed to investigate the heating effect of EIHS, the accurate electrochemical-thermal coupling model, validated against the charging capacity calibration with various C-rates and HPPC tests at different environments, was developed in depth to reflect the electrochemical and heat transfer behaviors of the LiB exposed to external cool air during the electromagnetic induction heating process. When the copper coil was subjected to a sinusoidal alternating current (SAC) excitation at 10 A, 3 kHz, the LiB can be warmed up to 293.15 K from 243.15 K within 742 s with an even heat generation inside the LiB. The impact of the SAC parameters on the needed heating time was illustrated with time maps, a series of contours suggested that the heating velocity increase with the increase of both the amplitude and frequency. As compared with the low-temperature state, the internal resistance had a more than 3-fold decrease, which can improve the discharging voltage platform and terminal voltage output, thus increasing the pulse power and usable capacity. Neither noticeable capacity retention difference before and after the heating cycles nor obvious capacity loss discrepancy between the normal charge-discharge and heating cycle tests was found at the end of the 200 heating cycles, so the EIHS can achieve a good tradeoff among temperature rising effect, working behaviors and LiB cycle lifespan, which had a considerable potential to enhance the applicability of EVs (electric vehicles) in frigid weather. Moreover, a better heat transfer condition, higher material thermal conductivity and lower specific heat capacity play an important positive role on the improvement of temperature rising performance.

Enhancing Biodiesel Production from Nyamplung Oil: Kinetic Analysis of Transesterification via Electromagnetic Induction Heating

Enhancing Biodiesel Production from Nyamplung Oil: Kinetic Analysis of Transesterification via Electromagnetic Induction Heating

Graphene synthesis by electromagnetic induction heating: Domain size and morphology control

In this paper we discuss the effect of hydrogen and methane content during low-pressure chemical vapor deposition (LPCVD) of graphene on inductively heated copper foils. By increasing the H2/CH4 ratio by a factor of 5 from 25 to 125, different graphene morphologies ranging from dendritic fractals to compact hexagonal islands are obtained. In addition, increasing the hydrogen concentration allows the nucleation rate to be slowed down by a factor of ∼10 thereby high-quality regular hexagonal graphene single crystals of significant size of 0.1 mm are found. From these measurements, we estimate the activation energy for graphene nucleation in low-pressure CVD (2 eV) and propose a phenomenological law for graphene nucleation. As compared to conventional CVD methods, considerable advantages of inductive heating are outlined, and some fundamental aspects of this approach are discussed.

A novel flexible catheter with integrated magnetic variable stiffness and actuation

Flexible instruments offer significant advantages over traditional rigid instruments in ophthalmic surgery, because they can achieve larger working space and minimize the risk of damage caused by contact with eye tissues. However, it also needs to be rigid to achieve sufficient surgical operation force and stability. In this study, we propose a novel flexible catheter with integrated magnetic variable stiffness and actuation, based on electromagnetic induction heating and phase change alloy. The experimental results show that the catheter can switch from rigid to flexible modes in 11 s, and it takes 10 s to switch from flexible to rigid modes in room temperature. The bending stiffness of the catheter is 930.23°N mm2 in rigid mode and 74.42°N mm2 in flexible mode. In addition, the catheter can limit the axial force below 0.08°N in flexible mode, while withstand a force greater than 1.08°N in rigid mode. The catheter is equipped with a magnetic tip that can safely navigate in flexible mode with maximum bending angle of 106 degrees. The phantom experimental results demonstrated the potential clinical value of the proposed catheter.

Monolithic Catalyst of Ni Foam-Supported MnOx for Boosting Magnetocaloric Oxidation of Toluene.

Catalytic oxidation has been considered an effective technique for volatile organic compound degradation. Development of metal foam-based monolithic catalysts coupling electromagnetic induction heating (EMIH) with efficiency and low energy is critical yet challenging in industrial applications. Herein, a Mn18.2-NF monolithic catalyst prepared by electrodeposition exhibited superior toluene catalytic activity under EMIH conditions, and the temperature of 90% toluene conversion decreased by 89 °C compared to that in resistance furnace heating. Relevant characterizations proved that the skin effect induced by EMIH encouraged activation of gaseous oxygen, leading to superior low-temperature redox properties of Mn18.2-NF under the EMIH condition. In situ Fourier transform infrared spectroscopy results showed that skin effect-induced activation of oxidizing species further accelerated the conversion of intermediates. As a result, the Mn18.2-NF monolithic catalyst under EMIH demonstrated remarkable performance for the toluene oxidation, surpassing the conventional nonprecious metal catalyst and other reported monolithic catalysts.

Removal of metal impurities from diamond wire saw silicon powder by vacuum electromagnetic directional solidification

The utilization of high-purity silicon (∼99.9999 %) is prevalent in the solar photovoltaic sector, and achieving a reduction in its cost has emerged as a pivotal engineering objective within the silicon solar industry. Recycling silicon from diamond wire saw silicon powder (DWSSP) is a promising solution to fulfill the continuously expanding of high purity silicon demand. Vacuum directional solidification technology using high-frequency electromagnetic induction heating was proposed to purify DWSSP for the first time efficiently. The silicon melt and gas interface reaction, as well as metal impurities’ microsegregation in silicon ingot were observed. The effects of vacuum level and electromagnetic force on the separation of silicon and metal impurities were investigated using thermodynamics and electromagnetic mechanics. Results indicate that the content of oxygen in the silicon reduced from 30.91 wt% to 5.08 wt%, and the actual sample composition including for uptake of residual gas contamination steadily declined as the vacuum level increased from 600 Pa to 10 Pa. Vacuum electromagnetic directional solidification reduced the content of metal impurities from 641 ppmw to 29.80 ppmw, increases the proportion of crystalline silicon area, and makes the silicon lattice arrangement more regular.

Study on temperature field distribution state of carbon fiber reinforced polymer wound circular tube via electromagnetic induction heating

The variation of temperature fields during the winding process of CFRP (Carbon Fiber Reinforced Polymer) due to fiber winding is a key factor influencing its curing and shaping. Traditional heating methods result in energy wastage and environmental pollution during the heating process. Electromagnetic induction technology, as a non-contact, pollution-free, and efficient heating method, is playing an increasingly significant role in the process of heating and curing CFRP. This study focuses on two heating methods, internal and external, for CFRP wound circular tubes. It establishes finite element analysis models for induction heating with different coil structures. The heating mechanisms of different coil-induced CFRP wound circular tube models are explained, and the effects of external arc-shaped coils and external/internal annular coils on the temperature field distribution of CFRP wound circular tubes are investigated. By comparing simulations with experiments, the correctness of the numerical analysis model in this study is demonstrated. It offers viable heating methods for different conditions in industrial production, providing theoretical support and empirical data for the induction heating of CFRP wound circular tubes.

Research on the Improvement of Lithium-Ion Battery Performance at Low Temperatures Based on Electromagnetic Induction Heating Technology

As the major power source for electric vehicles (EVs), lithium-ion batteries (LiBs) suffer from the degradation of technical performance and safety at low temperatures, which restricts the popularization of EVs in frigid regions. Thus, this study developed an extremely fast electromagnetic induction heating system in order to improve the poor performance of LiBs in cold weather. An electrochemical–thermal coupling model (ETCM), validated against the experimental results of charge and discharge, which successfully predicted LiB voltage, temperature, and other physical characteristics at various ambient temperatures, was established in COMSOL Multiphysics 6.0 as a development tool for evaluating the heating effect of the system. When the copper coil is subjected to a SAC (sinusoidal alternating current) of 8 A and 50 Hz, the LiB can be heated from 243.15 to 293.15 K within 6 min with an instantaneous temperature increase rate of 0.263 K/s and a homogeneous temperature distribution. The results of the capacity calibration, cyclable lithium detection, and HPPC simulation show that the heating method can visibly increase the Li+ concentration inside the active particle, and there was only a tiny concentration gradient on the surface of the particle. In addition, the internal resistance was approximately a quarter of that without heating; therefore, both the discharge energy and specific power boost were two times higher than the original level. Compared to the normal charge–discharge cycles at 293.15 K, the capacity retention of the LiB only decreased by 0.23% after 60 consecutive heating cycles, so the heating method can balance the temperature rise, work capacity, and LiB health. Furthermore, the improvements in the thermal insulation condition and material thermal conductivity are two feasible ways to optimize the temperature-increase effect.

Understanding CO2 reduction via reverse water-gas shift triggered by electromagnetic induction at moderate condition

Electromagnetic induction heating (EMIH) boosted highly selective reduction of CO2 into CO on Fe fiber-based catalysts, via reverse water–gas shift (RWGS) proceeding at milder condition than traditional heating. Doping Ru promoted catalytic performance, and among them the optimal content of nominal Ru loading was 3 %. In system of EMIH-driven RWGS on 3 %Ru/Fe, the demanded temperature of reaction bed for about 40 % CO2 conversion decreased by 100 °C compared to traditional heating-driven RWGS. By employing in-situ characterizations configured with EMIH module, it was found that the alternating electromagnetic field deflected EMIH-induced current eddy causing electron enrichment on surface of catalyst. On the electron-rich surface of catalyst, RWGS reaction driven by EMIH obeyed HCOOH-intermediated mechanism, which faced lower energy barriers than the redox pathway underwent by traditional heating driven-RWGS.

Experimental investigation supported by artificial neural networks (ANNs) for predicting the heating performance of a cyclone separator coupled with induction heating coil

This paper proposes a novel dust separation and thermal inactivation system that couples an electromagnetic induction heating coil with a cyclone separator. The idea is aimed at the thermal inactivation of potential microorganisms (viruses and other pathogens) associated with dust-laden gas streams, particularly from road surfaces. The integrated system was tested in an experimental setup as a proof-of-concept investigation at different cyclone-induction heating temperatures of 100–400 °C (373–673 K) and air discharge flow velocities of 5–30 m/s. In addition, the influence of operating parameters such as cyclone heating temperature (as induction heating inputs), inlet air velocity, and heating time on the efficacy of the induction heating process were investigated. The time-averaged temperature measurements along the axial direction (z-down) showed predominant temperature fluctuations in the cylinder and cone sections for all cases, especially when the gas plummets down the cyclone. Temperature was highest in the conical section (z = 525 mm) at 320 °C (593 K) at 5 m/s and lowest in the outlet section (z = 375 mm) at 185 °C, which was expected. The results show that inlet air velocity plays a crucial role in affecting temperature dynamics. Conclusive results indicate that with increasing temperature, pressure drop decreases significantly. Along with the experimental results, multiple regression indices using an Artificial Neural Network (ANN) modeling were used to predict the cyclone’s induction heating performance, showing good prediction quality in terms of the mean square errors (MSE and RMSE) and the correlation coefficient R2: 0.99. The study demonstrates the technical viability of integrating induction heating coil to a cyclone separator for wide temperature applications.

Oxidation behavior and intermetallic compound growth dynamics of SAC305/Cu solder joints under rapid thermal shock

Oxidation behavior of SAC305/Cu solder joints and kinetics of intermetallic compound (IMC) growth were investigated using an electromagnetic induction heating device. The results show that the solder joint undergoes oxidation when subjected to rapid thermal shock. The oxidation behavior of the solder joint itself is the main factor, which is exacerbated by the presence of the internal Cu6Sn5 IMC. The growth of the Cu6Sn5 layer is controlled by grain boundary diffusion, while that of the Cu3Sn layer is controlled by bulk diffusion. The dissolved Cu of the substrate diffuses mainly into the interfacial IMC and the interior of the solder. Under rapid thermal shock, the shear strength of the solder joint decreases substantially, by 49.2% after 72 h. The fracture mechanism changes from ductile fracture to mixed tough−brittle fracture and finally, to brittle fracture.