Depleted uranium oxide supported nickel catalyst for autothermal CO_(2)methanation in non-adiabatic reactor under induction heating

Undoped nickel-based catalysts supported on depleted uranium oxide allow one to carry out CO_(2)methanation process under extremely low reaction temperature under atmospheric pressure and powered by a contactless induction heating.By adjusting the reaction conditions,the catalyst is able to perform CO_(2)methanation reaction under autothermal process operated inside a non-adiabatic reactor,without any external energy supply.Such autothermal process is possible thanks to the high apparent density of the UO_x which allows one to confine the reaction heat in a small catalyst volume in order to confine the exothermicity of the reaction inside the catalyst and to operate the reaction at equilibrium heat in-heat out.Such autothermal operation mode allows one to significantly reduce the complexity of the process compared to that operated using adiabatic reactor,where complete insulation is required to prevent heat disequilibrium,in order to reduce as much as possible,the heat exchange with the external medium.The catalyst displays an extremely high stability as a function of time on stream as no apparent deactivation.It is expected that such new catalyst with unprecedented catalytic performance could open new era in the field of heterogeneous catalysis where traditional supports show their limitations to operate catalytic processes under severe reaction conditions.

Research on the heat conduction mechanism of induction brazecoating

Induction brazecoating technology is an important means to improve the surface properties of materials.In this paper,copper plate and corundum are selected as substrates for induction brazecoating respectively.The temperature variation of powder and paste coating is systematically studied,and the heat conduction mode and path in the brazecoating process are analyzed.The results show that rise of the coating temperature mainly depends on the heat absorption from the substrate.The liquid-solid interface conducts heat violently and advances step by step,which promotes the melting spread of metal filler metal.The powdery brazecoating material is in a free state,and there is a gas insulation film between the powder particles and the diamond,making it difficult for substrate to conduct heat to the coating.The binder not only assists forming,shell making and oxygen isolation,but also plays an important role during melting.

SIMULATION OF TEMPERATURE FIELD IN ULTRA-HIGH FREQUENCY INDUCTION HEATING AND VERIFICATION

An experimental and numerical study on the temperature field induced in the ultra-high frequency induction heating is carried out.With an aim of predicting the thermal history of the workpiece,the influence factors of temperature field,such as the induction frequency,the dimension of coil and the gap between coil and workpiece,are investigated considering temperature-dependent material properties by using FLUX 2Dsoftware.The temperature field characteristic in ultra-high induction heating is obtained and discussed.The numerical values are compared with the experimental results.A good agreement between them is observed with 7.9% errors.

Feasibility Research on Application of a High Frequency Induction Heat to Line Heating Technology

The purpose of this paper is to investigate the feasibility of high-frequency induction heat for the line heating process through a series of experimental studies and numerical calculations. The results show that the heating temperature of induction heating meets the demands of steel plate bending, and the deformation of a steel plate heated by induction heating can achieve the same effect as flame heating. Meanwhile, the finite element model of moving induction heating of the plate is developed, and the comparison of the residual strain fields and transverse shrinkage between these two kinds of heating shows that great similarity has been achieved.

Conversion of induction heating temperature from ANSYS to DEFORM

In the production of hot extrusion pipes, the billet will be heated in an induction furnace, before piercing or extrusion,to a certain temperature. The induction heating temperature field profile in the billet will exert an influence on the deformation processes. The study has developed an data conversion program to convert the temperature data from induction heating by ANSYS to deformation simulation software DEFORM; therefore, not only the relatively accurate temperature field can be made available, compared with the usually assumed uniform temperature field, but also the connection between induction heating and deformation can be established, which is essential to evaluate the processing parameters. Numerical simulation of the piercing processes of different temperature fields by induction heating was carded out, and the results have shown that the different initial temperature fields in the billet can lead to different deformation curves, which indicates that the conversion program is necessary to study the production process of hot extrusion pipes.

Mathematical modeling of induction heating of discard substitution block for billet hot extrusion process

A magnetic and temperature field-coupled mathematical model is proposed to calculate the induction heating process of a discard substitution block for billet hot extrusion process. The mathematical model is validated by comparing simulation results with temperature measurements recorded during physical modeling. Based on systematical analysis of calculation results, a quantitative sawtooth induction power curve was proposed to realize the aim of achieving the best distributed temperature field in the block within the shortest induction time.

Magnetic Oil Thermal Behavior under Electromagnetic Induction for Energy Efficient Heating System Design

This study describes thermal behavior of magnetic lubricant oil under electromagnetic induction. Experimental set up include oil pump, oil tank, induction heating unit, and heat exchanger. It is a closed loop system where the oil pump circulates oil through oil tank to the system, at the same time induction heating unit heats up to the heat exchanger where the lubricant oil thermal behavior is examined. The unit has been largely studied and tested both magnetic and regular motor oil in a laboratory environment and promising results have been obtained for an actual indoor floor to space heating system design.

Progress on research of induction heating in Baosteel

Owing to the development of new products and higher requirement of product properties, the current existing induction heating technology of Baosteel can no longer satisfy the new requirements of the product line. Control of the induction heating temperature to an appropriate value is a key consideration in induction heating technology. To obtain acculturated temperatures, investigations were focused on the parameters of an induction heating system, including those of induction heating equipment and heating processes. In these investigations, computer simulation was used to model the induction heating process, followed by physical experimentation to verify and improve the simulation model; finally, optimized induction heating parameters were suggested. The use of computer simulations dramatically decreased physical experimental times, and the computed heating parameters were used to guide the physical experimentation and design of the product line ; this increased the efficiency of subsequent investigations. This study focuses on the development of induction heating technology in Baosteel, which includes the overall induction heating technology used in manufacturing backup rollers and in the thermomechanical control process.

Zero-voltage switching converter absorbing parasitic parameters for super high frequency induction heating

This paper presents a novel mega-Hz-level super high frequency zero-voltage soft-switching converter for induction heating power supplies. The prominent advantage of this topology is that it can absorb both inductive and capacitive parasitic components in the converter. The switch devices operate in a zero-voltage soft-switching mode. Consequently, the high voltage and high current spikes caused by parasitic inductors or capacitors oscillation do not occur in this circuit, and the high power loss caused by high frequency switching can be greatly reduced. A large value inductor is adopted between the input capacitor and the switches, thus, this novel converter shares the benefits of both voltage-type and current-type circuits simultaneously, and there are no needs of dead time between two switches. The working principles in different modes are introduced. Results of simulation and experiments operated at around 1 MHz frequency verify the validity of parasitic components absorption and show that this convener is competent for super high frequency applications.

Numerical analysis on Joule heating of double-loop channel induction furnaces

In order to investigate Joule heating power,a three-dimensional finite element model(FEM) was developed to predict Joule heating power in the channels of double-loop inductor. The simulated results were compared with experimental data from low load trials for a 400 kW inductor. The results,such as power factor and Joule heating power,show reasonable correlation with experimental data,and Joule heating rate reaches the maximum at the corners and the minimum at the centre of the cross-section area. With increasing relative permeability of iron core,length of coils,current frequency and resistivity of metal melt,the power factor and Joule heating power change. It is concluded that current frequency,the resistivity and length of the coil play a critical role in determining the power factor and Joule heating power,whereas relative permeability of the magnetic core shows no significant influence on them.

Formation and wear behaviors of in-situ Al3Ti/Al composites using aluminum and titanium fibers under electromagnetic induction heating

Under various electromagnetic induction heating powers,different Al3Ti/Al composites were fabricated by in-situ synthesis method from aluminum and titanium fibers.Microstructures and particles distribution of the composites were examined by XRD,SEM and EDS.The results show that no other intermetallic compounds beside Al3Ti can be in-situ synthesized.Around the titanium fibers,the reaction zones and diffusion zones can be obviously found.Due to the stirring of the electromagnetic function,the formation of the micro-cracks inside the reaction zone was conducive to the peeling off of the Al3Ti particles,and ensures the continuous reaction between liquid aluminum and titanium fibers,as well as the diffusion of Al3Ti particles.At the same time,there were secondary splits of Al3Ti particles located in diffusion zones.Two-body abrasion test shows that with the increase of induction heating power,the wear rates of the composites reduced and the number of grooves decreased.

A Study on the Effective Long Type Coil Shape by Multidisciplinary Method in Induction Heating

The axis symmetric analysis method can neither handle initial curved plates nor be used in the optimization of coil shapes because an axis symmetric coil is the only shape to analyze in this method. But the method using some discrete divisions and steps, can overcome these difficulties and show more accurate, reasonable results of temperatures and deflections in flat or curved plates with initial curvature, than those in the axis symmetric analysis method. Traditionally, the coil shape in induction heating is circular shape and it needs the moving process along heating lines. To overcome these, the “long type coil” with some linear parallel coils is proposed. It does not need the moving process along heating lines and reduces the heating process time. The results of experiments are compared with those of simulation.

FEM-BEM Coupling for the Modelling of Induction Heating Processes Including Moving Parts

Every electrical conductive medium placed in a time varying magnetic field is the seat of eddy currents that dissipate power through Joule effect. The induction hardening process takes advantage of this effect. The power concentrates in the surface of the piece (skin effect), the thickness of which depends on the electromagnetic properties and the frequency of the currents. The numerical simulation of such a process is of major interest to control and estimate the thickness of the treated layer, the superficial hardness, the residual stresses (often compressive in the surface) or the residual distortions. In this paper we focus on the interactions between electromagnetism and heat transfer for the simulation of the heating stage. The method used to couple both phenomena is detailed. A magnetic vector potential formulation is used for the electromagnetic analysis and an approach coupling finite elements with boundary elements is presented. Such a method is especially useful when moving parts are involved as it is generally the case for induction hardening processes. The air is represented by a boundary element that enables to consider independent meshes for all the conductive media within the device (piece and coils). Moreover, meshes are now the same for the electromagnetic and thermal analyses. This considerably facilitates the analysis that is performed step by step, each step corresponding to a position of the moving media. At each step, the matrices associated with the boundary element are calculated and the magneto-dynamic and thermal analyses are performed. Finally, an application is presented.

A Numerical Model Coupling Electromagnetism and Thermomechanics Application to Induction Heating Modeling

A numerical model coupling the various physical phenomena (electromagnetic, thermal and mechanical) taking place in the induction heating process has been developed. The mathematical model and the numerical methods are presented here, along with some results ( electric, thermal and mechanical fields in the workpiece)

Numerical simulation of the induction heating of a magnesium-alloy round billet

A mathematical model of the transient electro-thermal coupling of the induction heating of a magnesiumalloy round billet is established herein. The heating curve and temperature distribution characteristics of a magnesium alloy were calculated during induction heating under different parameters. Factors such as the number of coil turns and the cooling conditions were analyzed. A method for optimizing the temperature control mode and coil length of the magnesium-alloy round billet is proposed. The length of the coil and corresponding heating mode are determined through the coil length ratio( CLR),which provides a theoretical basis for the optimization of the magnesium-alloy round billet's extrusion.

Failure Modes of Lead Free Solder Bumps Formed by Induction Spontaneous Heating Reflow

The shear failure modes and respective failure mechanism of Sn3.5Ag and Sn3.0Ag0.5Cu lead-free solder bumping on Au/Ni/Cu metallization formed by induction spontaneous heating reflow process have been investigated through the shear test after aging at 120℃ for 0, 1, 4, 9 and 16 d. Different typical shear failure behaviors have been found in the loading curves （shear force vs displacement）. From the results of interracial morphology analysis of the fracture surfaces and cross-sections, two main typical failure modes have been identified. The probabilities of the failure modes occurrence are inconsistent when the joints were aged for different times. The evolution of the brittle NiaSn4 and Cu-Ni-Au-Sn layers and the grains coarsening of the solder bulk are the basic reasons for the change of shear failure modes.

Experimental study of induction heating for steel plates

The temperature distribution of steel plates is affected by heating rates and heating curves in the process of induction heating.The magnetic flux density inside the induction furnace was measured,the distribution of magnetic flux density was analyzed and the uniform area of the induction heating temperature distribution was ascertained.The locations for measuring temperature were set and the temperature in different processes was measured.The influence of heating rates and heating curves on the temperature difference of steel plates was studied.The experimental results showed that the steel plates’ temperature difference increased with the increase of the heating rate.The temperature difference was obviously affected by different heating curves when the heating rate was the same.A suitable heating curve would be beneficial to reduction of steel plates’ temperature difference.

The use of induction heating in hot-rolling operations

The use of induction heating in the hot-rolling of slabs,bars,billets,and blooms is presented.In today' s world,the cost of fossil fuels and the impact on the environment is an increasing concern.Induction heating can be used to heat materials from ambient temperature or in conjunction with gas reheat furnaces to enhance flexibility, boost productivity,reduce space requirements,improve metal surface quality,increase energy efficiency,and reduce harmful emissions to the environment.Various possible locations for induction heating are shown.An example case study is presented to quantify an increase in output.Some basic concepts of induction heating are explained to provide metallurgists with a better understanding of how and where induction heating can be applied.A brief introduction to computer modeling and control is touched on.Finally,some examples of recent installations are presented.

Effects of induction heating temperature fields on 321 stainless tubes during the expansion process

Expansion is an important operation in the hot extrusion production line of seamless steel tubes, which is to produce proper hollow billets for extrusion. The billet goes through induction heating before expanded to acquire a proper temperature. In this study, the effects of three types of inhomogeneous temperature fields on 321 stainless tubes during the expansion process were simulated. The results have indicated that it was an optimum temperature filed for expansion, where the temperature varied linearly along radial direction and the temperature was lower on the inner surface. This temperature field is beneficial to improving the stability of expansion and ensuring dimensional accuracy and increasing the utilization rate of tubular billet material.

Scanning Based Induction Heating for AISI 4340 Steel Spline Shafts-3D Simulation and Experimental Validation

This paper presents an investigation of non-stationary induction heating process applied to AISI 4340 steel spline shafts based on 3D simulation and experimental validation. The study is based on the knowledge, concerning the form of correlations between various induction heating parameters and the final hardness profile, developed in the case of stationary induction heating. The proposed approach focuses on analyzing the effects of variation of frequency, power and especially scanning speed through an extensive 3D finite element method simulation, comprehensive sensitivity study and structured experimental efforts. Based on coupled electromagnetic and thermal fields analysis, the developed 3D model is used to estimate the temperature distribution and the hardness profile. Experimentations conducted on a commercial dual-frequency induction machine for AISI 4340 steel splines confirm the feasibility and the validity of the proposed modelling procedure. The 3D model validation reveals a great concordance between simulated and measured results, confirms that the model can effectively be used as framework for understanding the process and for assessing the effects of various parameters on the hardening process quality and performance and consequently leads to the most relevant variables to use in an eventual hardness profile prediction model.