40KG Medium-Frequency Induction Iron Melting Furnace
I. Equipment Overview
Designed for university laboratories, research institutions, and precision material R&D scenarios, the 20kg medium-frequency copper melting furnace achieves efficient melting and composition control of red copper, brass, bronze, and other copper alloys based on electromagnetic induction heating principles. Integrated with an intelligent temperature control system and electromagnetic stirring function, the equipment meets the strict requirements for melting precision in new material R&D, microstructure research, and other experiments, occupying less than 1 square meter to fit compact laboratory layouts
II. Core Working Principles
1. Medium-frequency Induction Heating Mechanism
A medium-frequency power supply (frequency range 1-20kHz) converts three-phase 380V power frequency electricity into alternating current, which is input into a copper induction coil. The alternating magnetic field generated by the coil excites eddy currents in the copper charge, using the resistance heating effect of copper to achieve temperature rise (thermal efficiency ≥85%). The cold furnace melting time from room temperature to 1100ºC is approximately 30-40 minutes.
2. Electromagnetic Stirring Technology
Lorentz forces generated by the medium-frequency magnetic field drive directional flow of the copper melt, with stirring intensity automatically adjusted with frequency to ensure uniform distribution of alloy elements. Test data shows that in the melting of Cu-30Zn brass, electromagnetic stirring can reduce the zinc element segregation rate from 12% to below 3%.
III. Technical Parameters Table
| Parameter Category |
Technical Indicators |
| Rated Power |
60kW (adjustable, recommended power for copper alloys: 30kW) |
| Power Supply Voltage |
Three-phase 380V/50Hz |
| Frequency Range |
1-50kHz (auto-matching load) |
| Maximum Melting Capacity |
40kg (pure copper)/18kg (brass, due to density difference) |
| Temperature Control Accuracy |
±2ºC (using PID intelligent algorithm, fluctuation ≤±1.5ºC at 1100ºC constant temperature) |
| Furnace Body Material |
Inner layer: Mullite refractory castable (temperature resistance 1600ºC)
Outer layer: Cold-rolled steel plate + thermal insulation cotton (surface temperature ≤50ºC) |
| Melting Time |
Cold furnace: 30-40 minutes
Hot furnace: 20-25 minutes |
| Stirring Method |
Medium-frequency magnetic field electromagnetic stirring (3-level adjustable intensity) |
| Dimensions |
1200mm×800mm×1500mm (L×W×H) |
| Safety Protection |
Overload protection/water shortage alarm/over-temperature power-off/leakage protection |
IV. Processable Materials Range
1. Pure Copper and Single-phase Alloys
- Red Copper (T2): Copper content ≥99.9%, used for high-purity conductive material experiments
- Oxygen-free Copper (TU1): Oxygen content ≤0.003%, suitable for pretreatment of vacuum melting
2. Copper Alloy Systems
| Alloy Type |
Typical Composition |
Melting Point Range |
Application Scenarios |
| Brass |
Cu-60-70%Zn |
900-950ºC |
Corrosion-resistant component R&D, cutting performance testing |
| Bronze |
Cu-Sn 5-12% |
850-1000ºC |
Wear-resistant materials, ancient bronze ware imitation experiments |
| White Copper |
Cu-Ni 10-30% |
1100-1200ºC |
Seawater corrosion resistance research, resistance material preparation |
| Copper-aluminum Alloy |
Cu-Al 5-10% |
950-1050ºC |
High-temperature strength alloy design, phase transformation kinetics research |
3. Special Material Processing
- Supports melting and mixing of copper matrix composites (such as Cu-SiC particle-reinforced alloys)
- Adapts to precise control of alloy compositions containing volatile elements (such as Zn, Pb)
V. Functional Advantages Analysis
1. Research-grade Precision Control
- Programmable temperature curve: Supports presetting 10-stage heating/insulation procedures to meet step-by-step process requirements such as solution treatment of Cu-Ni alloys
- Data traceability system: Automatically records 15 parameters including temperature-time curves and power output, supporting USB export of Excel reports
2. Energy Saving and Efficiency Optimization
- 40% more energy-efficient than resistance furnaces: At 30kW power, melting 20kg of red copper consumes approximately 15kWh
- Fast hot furnace start-up: Utilizes furnace body residual heat, shortening secondary melting time to within 20 minutes
3. Safety Protection System
- Triple interlock protection:
Hardware: Overcurrent protection circuit breaker (rated current 100A)
Software: Automatic power-off at over-temperature of 1150ºC
Mechanical: Tilting furnace limit switch + furnace cover safety lock device
VI. Typical Application Scenarios
1. Materials Science Research
- Case: A materials college of a university used this equipment for solidification structure control experiments on Cu-10Sn bronze. By adjusting the electromagnetic stirring intensity (5-15kHz), the dendrite spacing was successfully refined from 50μm to 20μm, with related achievements published in Materials Science and Engineering A.
2. Cultural Relics Restoration Field
- Used for reducing melting of ancient bronze ware (such as Shang and Zhou Dynasty Cu-Sn-Pb alloys). Temperature control accuracy ensures Sn element loss rate ≤1.5%, meeting the composition matching requirements for cultural relic imitation.
3. Electronic Packaging Materials
- Prepares high thermal conductivity copper-silver alloy (Cu-10Ag). Precise temperature control (±2ºC) controls Ag phase precipitation, enabling the material to achieve a thermal conductivity of 380W/(m·K), suitable for R&D of high-power chip heat dissipation substrates.
VII. Operation and Maintenance Guidelines
1. Standard Operation Process
- Place a graphite crucible (diameter 200mm×height 300mm) in the furnace
- Load the charge, close the furnace cover, and connect cooling water (pressure 0.15-0.2MPa)
- Input process parameters on the touch screen (e.g., brass melting: heating rate 10ºC/min to 920ºC, holding for 15min)
- Start the automatic program, and the system real-time displays temperature curves and power output
2. Maintenance Key Points
- Weekly inspection: Check if the induction coil waterway is scaled (deionized water is recommended)
- Monthly maintenance: Inspect furnace lining refractory materials for cracks (repair if exceeding 2mm)
- Annual calibration: Calibrate the accuracy of the temperature control meter (traceable to national standards)
VIII. Selection Comparison Reference
| Indicator |
Traditional Resistance Furnace |
Ordinary Medium-frequency Furnace |
This Equipment (Intelligent Type) |
| Temperature Control Accuracy |
±5ºC |
±3ºC |
±2ºC (intelligent PID) |
| Electromagnetic Stirring |
None |
Fixed intensity |
3-level adjustable + automatic matching |
| Data Recording |
Manual recording |
Basic data display |
Automatic storage + USB export |
| Energy Consumption |
25kWh/20kg |
18kWh/20kg |
15kWh/20kg (30% energy saving) |
| Suitable Scenarios |
Teaching demonstration |
Small-batch production |
Scientific research experiments + precision melting |
This equipment redefines the precision standards for laboratory copper alloy melting through technical integration and intelligent control, providing reliable melting process support for new material R&D. Whether for basic research requiring strict variable control or applied development pursuing composition consistency, its efficient, precise, and safe characteristics can meet the strict requirements of modern research laboratories.
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