ApplicationsHeat Casting Insert


A manufacturer of high quality aluminium castings in Sheboygan, WI, heating steel inserts for aluminium castings.

  • Excessive Cost - The existing process used induction heaters which cost $16,000 (1994).
  • Custom Fixturing - Induction heaters required special fixtures for each size of steel insert. The fixtures had to be replaced every 1.5 to 2.5 years at a cost of $300 to $800 each (1994).
  • Temperature Requirement - The steel had to be heated to at least the temperature of molten aluminium (1220F [660C]) to allow the aluminium to flow properly around the insert and to keep the aluminium from cracking at mounting or stress points as it cooled.
  • Time Constraint - Customer wanted to heat the steel insert to temperature in three minutes.
  • Heat - The steel inserts were heated with a Model 5209-10 High Density Infrared Heater.
  • Power Control - A Model 664F Phase Angle SCR Power Controller controlled the High Density Infrared Heater.
  • Decreased Cost - The Model 5209 High Density Infrared Heater and associated lamps, and the Model 664F Phase Angle SCR Power Controller had a total cost of under the cost of induction heaters.
  • Standard Fixturing - The High Density Infrared Heater used a single mounting fixture, eliminating the costs for custom fixturing.
  • Heating Capability - With the capability to heat objects to temperatures in excess of 3000F (1650C), the High Density Infrared Heater was able to heat the steel to the required temperature.
  • Speed - The steel was heated to temperature within the customer requirement of three minutes.