Induction Heating Research Articles

Customizable Induction Heating Profiles: from Tailored Colloidally Stable Nanoparticles Toward Multi‐Stage Heatable Supraparticles

AbstractMagnetic nanoparticles (NPs) are efficient heat mediators in induction heating. Originally explored for hyperthermia, their applications have broadened to industrial processes where temperature control is crucial. By adjusting the NP composition or morphology, magnetic characteristics such as Curie temperatures can be tailored, allowing control over maximum heating thresholds. These NPs are, however, usually designed for maximum heating rates at specific magnetic fields. In this work, the synthesis is presented for colloidally stable Co and ZnCo ferrite NPs with customizable maximum heating temperatures, and their combination within micron‐scaled supraparticles (SPs). Maximum induction heating temperatures of ZnCo ferrite NPs are tuned between 150 and 220 °C, while customization of Co ferrite species yields temperatures between 200 and 350 °C. These distinct magnetic properties are exploited in the selective multi‐stage heating of SPs consisting of both species. Here, ZnCo ferrite components heat up to a first temperature plateau at low alternating magnetic fields (AMF), while Co ferrite NPs reach higher temperatures at increased AMF. The precise control of induction heating thresholds through the adaptability of NPs offers a high degree of customizability which makes induction heating particularly attractive for applications requiring sequential or spatial heating, such as catalysis or debonding on demand.

Induction Coil Design Considerations for High-Frequency Domestic Cooktops

The use of wide band gap (WBG) semiconductor switches in power converters is increasing day by day due to their superior chemical and physical properties, such as electrical field strength, drift speed, and thermal conductivity. These new-generation power switches offer advantages over traditional induction cooker systems, such as fast and environmentally friendly heating. The size of passive components can be reduced, and the decreasing inductance value of induction coils and capacitors with low ESR (equivalent series resistance) values contributes to total efficiency. Other design parameters, such as passive components with lower values, heatsinks with low volumes, cooling fans with low power, and induction coils with fewer turns, can offset the cost of WBG power devices. High-frequency operation can also be effective in heating non-ferromagnetic materials like aluminum and copper, making them suitable for heating these types of pans without complex induction coil and power converter designs. However, the use of these new generation power switches necessitates a re-examination of induction coil design. High switching frequency leads to a high resonance frequency in the power converter, which requires lower-value passive components compared to conventional cookers. The most important component is the induction coil, which requires fewer turns and magnetic cores. This study examines the induction heating equivalent circuit, discusses the general structure and design parameters of the induction coil, and performs FEM (finite element method) analyses using Ansys Maxwell. The results show that the induction coil inductance value in new-generation cookers decreases by 80% compared to traditional cookers, and the number of windings and magnetic cores decreases by 50%. These analyses, performed for high-power applications, are also performed for low-power applications. While the inductance value of the induction coil is 90 μH at low frequencies, it is reduced to the range of 5 μH to 20 μH at high frequencies. The number of windings is reduced by half or a quarter. The new-generation cooker system experimentally verifies the coil design based on the parameters derived from the analysis.

Research on performance of porous scaffold-based getter activated by induction heating and its application in MEMS device

Non-evaporable getter (NEG) is widely used in vacuum packaging. However, there are two main contradictions. Firstly, the contradiction between bonding temperature of the device and activation temperature of the getter results in the getter being activated first and then packaged, and cannot be repeatedly activated, which seriously reduces the adsorption capacity and life of the getter. Secondly, the contradiction between the small package volume and the large adsorption capacity, how to integrate large adsorption capacity getter in a small space is a tricky problem. In view of the above contradictions, a porous scaffold-based getter activated by induction heating was proposed in this paper, results show that when nickel plating is used as the induction heating layer, the temperature can quickly rise to 700 °C within 10 s, and 1 μm Ti getter can be fully activated for 7 min. The good periodicity of the temperature curves proved that the nickel layer has good repeatable heating characteristics. In addition, the adsorption performance of the getter was tested and characterized at device level. The device level characterization of optical deflection method proves the effectiveness of induction heating to activate getter, which lays a foundation for the application of getter on MEMS devices.

Biomass-derived SiOx/C nanocomposite anode synthesis by induction heating for lithium ion battery

Biomass-derived SiOx/C nanocomposite anode synthesis by induction heating for lithium ion battery

Effect of Induction Heating Temperature on the Microstructures and Properties of GH4169 Alloy

Effect of Induction Heating Temperature on the Microstructures and Properties of GH4169 Alloy

The impact of induction heating time on the temperature distribution of high-temperature alloy discs

Abstract The induction heating time is directly related to the temperature uniformity of high-temperature alloy disc components. Therefore, investigating the influence of induction heating time on the temperature field distribution of disc components provides guidance for temperature control strategies in the forming process. In this study, the finite element analysis software COMSOL Multiphysics was employed to examine the impact of induction heating time on the radial and thickness-wise temperature fields of GH4169 discs. The results indicate that the heating time affects the thickness of the heating layer, and appropriately extending the heating time can improve the temperature uniformity in the thickness direction, achieving a temperature difference of ±5 °C in the disc component thickness direction under certain conditions. When the heating time ranges from 1229 s to 1239 s, the temperature in the R=30 mm to R=100 mm range reaches the suitable forging temperature.

High-Power/High-Temperature Fluid Water Induction Heating System based on a SiC-MOSFET Single-Ended High-Frequency Resonant Inverter

High-Power/High-Temperature Fluid Water Induction Heating System based on a SiC-MOSFET Single-Ended High-Frequency Resonant Inverter

Individualized Nutritional Management Using Dishcook Improves Nutrition Status Markers in Patients with Intellectual Disability.

Dishcook is a new cooking system that allows individual cooking using a dedicated induction heater. This study investigated whether Dishcook use affects the nutritional value of individuals with intellectual disabilities. This study was conducted on users receiving support from a continuous-employment office in Obama City, Fukui Prefecture, in 2022. Of these participants, 18 (seven women and 11 men) who requested the use of the Dishcook were included in the analysis. The study period was from January to August 2023. The mean age was 48.72±16.24 y. A significant increase in the overall phase angles of the limbs was observed. Triglyceride, LDL cholesterol, HbA1c, and serum zinc levels improved in patients who used the Dishcook. The phase angle obtained using Bioelectrical Impedance Analysis also improved, indicating the usefulness of the Dishcook in treating metabolic diseases and the possibility of individualized nutritional management.

Research on a New Inverter Control Strategy of Induction Heating Power Supply

To achieve “high voltage, low current” in the induction heating power circuit, enhance the flexibility of component selection in the circuit, and improve the quality of the inverter’s output waveform, a new control strategy of a single-phase NPC three-level inverter with unipolar frequency-doubling SPWM method is proposed. With the series connection of IGBTs in a single-phase NPC three-level inverter, the voltage withstand requirement of IGBT is reduced by half. The middle four IGBTs are controlled using unipolar frequency-doubling SPWM, while the outer four IGBTs are turned on later and turned off earlier to address the neutral point voltage imbalance issue in the inverter. Simulation results show that, compared with the traditional bipolar SPWM-controlled single-phase full-bridge inverter, the DC-side input voltage of the inverter can be double, and the current flowing through the entire circuit can be halved under the same output power using the proposed method.

Induction assisted autogenous plasma arc welding of HSLA steel

In this work, a high frequency induction heating (HFIH) assisted plasma arc welding (IPAW) technique is proposed to weld 6 mm thick S690QL high strength low alloy steel plates in square butt joint configuration and without using any filler material. A 3D finite element based coupled electromagnetic-thermal analysis is carried out to ascertain the weld's thermal characteristics. Microstructure evolution and mechanical performance are investigated using scanning electron microscopy, electron back scattered diffraction, transmission electron microscopy, tensile test, Charpy impact test and micro hardness test. The results demonstrate that 15 s initial static heating using a co-directional current coil with magnetic flux concentrator predominantly improves the weld penetration by 48 % and joint efficiency reaches 90 % to the base plate strength. Microstructural study shows that the addition of HFIH promotes low angle grain boundaries (LAGB) with bainite ferrite and granular bainite micro-constituents in the fusion zone, which causes localised yielding and failure in this zone during tensile test. Further investigation reveals that the HFIH encourages the formation of BI-type bainite ferrite laths of 1.3–2.2 μm width, combined with slender martensite-austenite (M-A) island at the bainite ferrite lath boundaries. The results also reveal that the induction heating promotes the formation of M23C6 precipitates and B2 structured Cu-enrich nano precipitates in the fusion zone (FZ). The microhardness distribution indicates that the FZ and coarse grain heat affected zone are significantly reduced due to the assistance of the HFIH. The impact test result shows a lower energy absorption by the IPAW weldments due to dominance of the LAGB with unfavourable strain distribution.

Microstructure forming mechanism of inconel 625 alloy fabricated by laser/ultra-high (UHF) induction hybrid deposition method

To reveal the microstructure forming mechanism of laser/ultra-high frequency (UHF) induction deposition, this paper developed a microscopic phase-field (PF) model to numerically investigate dendrite growth during solidification. The macroscopic model of molten pool evolution is adopted to provide the solidification conditions for the microscopic PF model. The dendrite growth during laser deposition is simulated to evaluate the effect of UHF induction heat on the dendrite growth. Results show that because of the high temperature gradient and cooling rate, the PDAS of laser-UHF induction hybrid deposited layer is less than that of the laser deposited layer. The UHF induction heat also leads to a high flow velocity of the molten metal during laser-UHF induction hybrid deposition. The high flow velocity contributes to the decrease in PDAS by inhibiting the interdendritic enrichment of solute. During laser-UHF induction hybrid deposition, a higher solute gradient is present in the tip region of dendrite arm, leading to a faster dendrite growth rate. The UHF induction heat also increases the solute distribution coefficient during deposition, which further inhibits the element segregation. Under the action of UHF induction heat, a low interdendritic solute gradient and an evenly distributed solute can be obtained, thus helping increase interdendritic undercooling degrees and decreasing the PDAS. The simulated PDAS and solute distribution have good consistency with the experimental results. The spectral analysis of EDS line detection indicates that the laser-UHF induction hybrid deposited layer has a more refined microstructure and weaker element segregation than the laser deposited layer does.

Magnetic shielding properties of an iron-based nanocrystalline alloy for induction heating systems

A nanocrystalline alloy, with an iron-based composition (Fe58.5Si16.7B6.5Nb5.1Cu13.2) and a Curie temperature of 570 °C, was investigated for its effectiveness as magnetic shielding films in an induction heating system. The primary focus of the research was to evaluate the shielding performance of the 3-turned (9-layered) shielding films with dimensions of 135 mm × 17 mm × 0.15 mm. Upon winding, these films formed a cylindrical structure that enveloped the coil, with a diameter of 13.9 mm and a height of 17 mm. The results showed that increasing the degree of fragmentation within the nanocrystalline shielding films significantly reduced the magnetic permeability by decreasing the real component from 11,500 to 400 and the imaginary part from 2800 to 20. However, a lower degree of fragmentation led to a 10 % increase in the resistance (Rs) of the heating module, although this effect was less pronounced as the relative permeability continued to increase. Furthermore, observations on preheating time to a set temperature of 400 °C and total energy consumption over a duration of 250s revealed an initial downward trend, followed by a rapid increase that even exceeded the initial values as the magnetic permeability of the nanocrystalline shielding films augmented. Notably, the study emphasized that nanocrystalline shielding films with a relative permeability value of 1000 demonstrated exceptional magnetic shielding performance, resulting in a 12.5 % reduction in preheat time and 7 % less energy consumption during preheating. In addition to empirical findings, the study developed a theoretical model elucidating the shielding mechanism inherent in induction heating systems. This model serves as a robust framework for the application of nanocrystalline shielding materials in such systems, laying the groundwork for enhanced magnetic shielding capabilities in future applications.

Characterization of an Induction Heating System Used as Solar Simulator

This report delves into the thermal behaviour of solar receiver tubes under induction heating, a key component in concentrated solar power (CSP) technology. Experimental investigations were conducted to understand the temperature distribution and challenges associated with induction heating. A stainless-steel tube was heated using an inductor and subjected to airflow. Initial tests revealed temperature deviations caused by the electromagnetic field and thermocouple interference. Adjustments were made in subsequent trials, including thermocouple repositioning, extended heating times, and consistent camera calibration. Additional experiments explored the effects of inserting iron plates in between the tube and the inductor coil. Results showcased varying temperature profiles for different configurations. In all the cases analysed, there is penetration of the magnetic field within the thickness of the tube walls, simplified as volumetric heat generation. Overall, these findings enhance our comprehension of induction heating dynamics to test CSP components in a small-laboratory scale that would potentially offer insights for system optimization.

Induction heating of unidirectional C/PAEK – A thermographic study on eddy current formation

Induction welding is an attractive assembly method for carbon fibre reinforced thermoplastic composites. Parts are heated through the electromagnetic induction of eddy currents in the electrically conductive network of carbon fibres. Such networks rely (partly) on interlaminar contact incidence between the carbon fibres for unidirectional ply-based composites, rendering eddy current formation stochastic. The present study aims to visualise this stochastic behaviour in order to gain deeper insights into the formation of eddy currents. To this end, various laminates were induction heated using a stationary coil while monitoring the heating patterns using a thermal camera. Similar behaviour was then replicated on ply-scale specimens using a strong direct current. The recorded thermograms highlight that eddy currents are predominantly induced along the different fibre directions present in the lay-up. Moreover, it was demonstrated that ply interfaces have a substantial impact on the (re)distribution of current density within the plies.

Preparation of bainite phase microstructure by laser-electromagnetic induction hybrid solid-state phase transformation

Increasing the proportion of bainite and martensite phases is one of the effective ways to enhance the toughness of medium-carbon low-alloy steel(42CrMo). In this paper, the surface heat treatment of 42CrMo steel is carried out by using a laser heat source to achieve complete austenitization, then with electromagnetic induction heating for several times to implement insulation, and eventually to promote bainite phase transformation. In conjunction with the temperature history curves, OM, SEM, and EBSD are used to characterize the bainite morphology and percentage of bainite via different parameters of the hybrid process. The results demonstrate that the hybrid process combined with twice electromagnetic induction heating can yield a considerable proportion of bainite phase in 42CrMo steel. The resulting duplex structure, consisting of bainite and a minor fraction of martensite, exhibits a significant increase (81.1%) in tensile strength, while maintaining similar impact toughness. The elongation after fracture only has a slight reduction of 5.5% compared to that of the substrate. This innovative process provides a practical alternative to traditional bainite isothermal treatment method which must perform in a heat treatment furnace. Therefore, it is presented as a promising solution for enhancing the mechanical properties of medium-carbon low-alloy high strength steels.

Study of the eddy currents effect in Spinning rotor Gauge

The Spinning Rotor Gauge (SRG) serves as a crucial tool in metrology as a secondary standard vacuum gauge. However, its lower measurement limit is not solely determined by background gas molecular friction damping but is also affected by other contributing factors, collectively termed residual damping. This paper investigates the influence of eddy currents on residual damping. It quantitatively analyzes the electromagnetic torque and eddy current heating power induced within the rotor’s interior and surface, calculates the corresponding kinetic energy loss, and simulates the rotor’s attenuation. The simulation predicts an attenuation of 0.23 Hz within a 12-hour period, corresponding to an average background pressure of 7 × 10-5 Pa. A comparison with observed residual damping data, showing an attenuation of 1.17 Hz and a background pressure of 1.6308 × 10-4 Pa, demonstrates high consistency. This affirms the reliability of the numerical model and calculation results regarding eddy current-induced residual damping presented in this article.

The Production of Porous Asphalt Mixtures with Damping Noise Reduction and Self-Healing Properties through the Addition of Rubber Granules and Steel Wool Fibers.

Conventional asphalt roads are noisy. Currently, there are two main types of mainstream noise-reducing pavements: pore acoustic absorption and damping noise reduction. However, a single noise reduction method has limited noise reduction capability, and porous noise-reducing pavements have a shorter service life. Therefore, this paper aimed to improve the noise-damping performance of porous asphalt mixture by adding rubber granules and extending its service life using electromagnetic induction heating self-healing technology. Porosity and permeability coefficient test, Cantabro test, immersion Marshall stability test, freeze-thaw splitting test, a low-temperature three-point bending experiment, and Hamburg wheel-tracking test were conducted to investigate the pavement performance and water permeability coefficients of the mixtures. A tire drop test and the standing-wave tube method were conducted to explore their noise reduction performance. Induction heating installation was carried out to study the heating rate and healing performance. The results indicated that the road performance of the porous asphalt mixture tends to reduce with an increasing dosage of rubber granules. The road performance is not up to the required standard when the dosage of rubber granules reaches 3%. The mixture's performance of damping and noise tends to increase with the increase of rubber granule dosage. Asphalt mixtures with different rubber granule dosages have different noise absorption properties, and the mixture with 2% rubber granules has the best overall performance (a vibration attenuation coefficient of 7.752 and an average absorption factor of 0.457). The optimum healing temperature of the porous asphalt mixture containing rubber granules and steel wool fibers is 120 °C and the healing rate is 74.8% at a 2% rubber granule dosage. This paper provides valuable insights for improving the noise reduction performance and service life of porous asphalt pavements while meeting road performance standards.

Skiing-inspired robust lubricating composite coatings from thermally sprayed ceramic template

Inspired by the mechanism of skiing, herein, a novel composite coating with excellent lubrication properties was developed by incorporating solid-liquid reversible lubricating phases into the inherent microcracks and pores of thermally sprayed ceramic coatings. The results indicate that the crystalline-amorphous heterostructure formed within the micro-nano cracks, enhancing their cohesive strength and toughness. Compared to traditional ceramic coatings, the friction coefficient of the composite coating has been reduced by 80 %, while the wear rate decreased from 2.89 × 10−4 to 6.44 × 10−7 mm3∙N−1∙m−1. Under the applied load and friction-induced heat, a thin liquid lubrication film is formed. Importantly, the lubricating phase continuously overflows from defects under the induction of frictional heat to replenish the lubricating film, ensuring long-term lubrication of the coating.

Synthesis and characterization of octahedron and cube shape Mn0.5Zn0.5Fe2O4 particle dispersion for magnetic fluid hyperthermia

The present work reports a synthesis of octahedron (A55NO) and cube-shaped (A55NC) Mn0.5Zn0.5Fe2O4 ferrite nanoparticle dispersion in distilled water. The crystal structure analyzed using powder X-ray diffraction (XRD) shows the crystallite sizes of 17.7 ± 0.4 nm and 11.9 ± 1.0 nm, respectively, for the A55NO and A55NC particles. The morphology as seen from transmission electron microscopy (TEM) confirms 17.8 ± 0.3 nm (σ = 0.27) and 8.7 ± 0.3 nm (σ = 0.33) edge lengths, respectively, for octahedron and cube-shaped particles. The thermogravimetric analyzer (TGA) and Fourier transform infrared (FTIR) spectroscopy are used to confirm the chemical binding of the surfactant with a sharp transition at 208.67 °C and 218.32 °C, respectively, for octahedron and cube-shaped particles, indicating the removal of the surfactant due to its decomposition from the particle surface. Both the particles are highly magnetic and have 75.32 Am2/kg and 72.93 Am2/kg saturation magnetization, as revealed by their M − H loops using a vibrating sample magnetometer (VSM). The stability of the sample is confirmed using the particle size analyzer (DLS) and the Zeta potential analyzer. The induction heating capacity of the fluid was investigated using the Embrell Easy Heat model LA6310 at 330 kHz. The heating response shows that even a minimum concentration of 1 mg/mL is sufficient to achieve the hyperthermic window temperature of 42 °C for both samples, which, unlike the same composition prepared by other routes, makes it impossible to go beyond 38 °C. Moreover, octahedron particle dispersion can reach this window temperature within 10 min, whereas cube particle dispersion requires only 15 min. The findings of this study hold significant practical value since it confirms that Mn0.5Zn0.5Fe2O4 composition with tuneable shape has the potential to work as a temperature-controlled magnetic switch for magnetic fluid hyperthermia under the defined safety limit with the minimum concentration.

Direct Growth of Vertical Graphene on Fiber Electrodes and Its Application in Alternating Current Line-Filtering Capacitors.

Fiber-shaped electrochemical capacitors (FSECs) have garnered substantial attention to emerging portable, flexible, and wearable electronic devices. However, achieving high electronic and ionic conductivity in fiber electrodes while maintaining a large specific surface area is still a challenge for enhancing the capacitance and rapid response of FSECs. Here, we present an electric-field-assisted cold-wall plasma-enhanced chemical vapor (EFCW-PECVD) method for direct growth of vertical graphene (VG) on fiber electrodes, which is incorporated in the FSECs. The customized reactor mainly consists of two radio frequency coils: one for plasma generation and the other for substrate heating. Precise temperature control can be achieved by adjusting the conductive plates and the applied power. With induction heating, only the substrate is heated to above 500 °C within just 5 min, maintaining a low temperature in the gas phase for the growth of VG with a high quality. Using this method, VG was easily grown on metallic fibers. The VG-coated titanium fibers for FSECs exhibit an ultrahigh rate performance and quick ion transport, enabling the conversion of an alternating current signal to a direct current signal and demonstrating outstanding filtering capabilities.