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.
Solution
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.
Benefits
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.
