Induction Furnace Specs 1

[jvazquez87]

Im learning about induction furnaces and recently came across this site. I love it! i hope i can ask for help on things i can't quite find out on my own. So my first issue is im wanting to build a furnace for the purpose of casting steel in specific I'm wanting to be able to cast tool steel for use in the production of quality anvils and various other tools. I want to keep it small with a target casting ability of up to 200lbs in a single cast. So i have a few questions for the knowledgeable people here.

1.I know that induction furnaces use high quality copper tubing for the coils like here Link I'm trying to figure out how big of a furnace i will need to build to be able to cast up 200lbs of steel and also what size coils i would be ok to use. What are the acceptable wall thickness of copper for this type of application? What kind of volts/current would i need to power such a furnace? Any help is greatly appreciated.

2.Also for this amount of steel would i be able to use another source of heat such as a waste oil burner? mix with propane? i was thinking about using propane or oil and pressurizing it with pure oxygen instead of high pressure air... These are just ideas i thought about floating around and seeing if someone could help. Thank you for your time.

3.Finally for today i have a plant in my town that produces refractory material but they only produce it for the aluminum industry, from what I've learned they carry a high alumina mix for certain alloys that theoretically would be suitable for use in steel. Im wanting to stay with a crucible type of pour for the sake of ease and plan to build the tools that are needed as i dont think 200lbs would be too much for 2 people to handle. I'm definitely thinking about safety first and plan to make it as remote a process as i can realistically.

Ill see if i can draw up some ideas and get some input from you guys. Thanks hope to hear back soon.

 

[arunmrao]

Can you visit any nearby melting units and learn from them. You have to consider safety in operations .It will be good, if you take the assistance of an expert in the field.

The cost of experimentation and time lost will far exceed the cost of a refurbished induction melting unit.

I'm just one step away from being rich, all I need now is money.
( read somewhere on the internet)

 

[jwhit]

There should be numerous used production furnaces of sizes similar to what you need on the market. I would think that would be much quicker, easier and till labor is factored in, cheaper than building your own. Plus, you have a good sense that it will work when you power it up. There will be a learning curve involved in just the melting aspect of the project. Also, be certain of the alloys you want to cast, before you start producing anything. A little reverse engineering could go a long way towards a successful project.

 

[EdStainless]

We had multiple Inductotherm furnaces for melting 300# heats.
We could melt from cold charges in 35-40 min.
They were hydraulic tilt and coupled to nice variable frequency power supplies.

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Plymouth Tube

 

[arunmrao]

For a 100 kgs steel melting, you will need a 100k.w, 1000Hz furnace. Using alumina crucibles, I have not seen them being used. Coil voltage should be 1200-1500 V .



I'm just one step away from being rich, all I need now is money.
( read somewhere on the internet)

 

[jvazquez87]

Thank you guys for the swift responses.

Jwhit i am indeed looking into the ppe side of things and an trying to see if i can tour some plants toy get a better view of things and process. Reading is only half the view. By reverse engineering do you mean the furnace or the alloy?

Ed do you remember what kind they where as far as manufacturer/model for the power supplies?

Arunmrao thank you for the starting point. From what do you base those specs? Also for the coils do you know what thickness the walls need to be? Would i be able to use hvac copper?

 

[EdStainless]

Inductotherm, Rancocus, NJ
They were 1000kW, 1,000Hz base freq
We used solid high alumina crucibles with rammed backing.

= = = = = = = = = = = = = = = = = = = =
Plymouth Tube

 

[jwhit]

I was thinking in terms of the alloys used. It seems to me that cast tool steel might be a bit overkill for an anvil, more often than not cast iron was used. You may be able to make a superior product without going to an actual tool steel. If you did use tool steel would you be using an S type, shock resisting or something else?