When it comes to refining capacity and adaptability, medium - frequency induction furnaces exhibit distinct characteristics in comparison to ordinary electric arc furnaces.
Electric arc furnaces outperform induction furnaces in removing phosphorus, sulfur, and achieving deoxidation. In an induction furnace, the slag is cold, and its temperature is maintained by the heat from the molten steel. In contrast, electric arc furnaces generate hot slag, which is heated directly by the arc. This hot slag can effectively carry out dephosphorization and desulfurization tasks. Moreover, the slag in an electric arc furnace undergoes thorough diffusion and deoxidation, resulting in superior performance in these aspects compared to induction furnaces.
Electric arc furnaces tend to have a higher chlorine content. This is because, in the high - temperature region of the arc, ammonia molecules are ionized into atoms and then absorbed by the copper liquid. Induction furnaces, on the other hand, have a lower nitrogen content but a higher oxygen content than electric arc furnaces. Additionally, the fast - life value of alloys is higher in induction furnaces.
Induction furnaces generally have a higher yield of alloying elements compared to electric arc furnaces. At the high temperatures generated by the arc in electric arc furnaces, the volatilization and oxidation losses of elements are significant. The burning rate of alloying elements in induction furnaces is lower. This difference is particularly evident when dealing with returned materials charged into the furnace.
When an induction furnace is in operation, it can effectively collect the alloying elements present in the returned materials. In contrast, during the treatment in an electric arc furnace, the alloying elements in the raw materials are first oxidized into the slag and then transferred back to the molten steel from the slag, leading to a noticeably increased burning loss rate. For example, the aluminum yield in an induction furnace ranges from 92% to 96%, while in an electric arc furnace, it is between 85% and 90%. Similarly, for tungsten, the induction furnace offers a yield of 90% - 94%, compared to 85% - 90% in an electric arc furnace. The high - temperature arc causes a large loss of alloying elements due to volatilization, whereas induction furnaces, which melt alloy elements through induction heating, experience less loss.
Induction furnaces rely on the principle of induction heating to melt the metal charge, which prevents an increase in the carbon content of the molten steel. Electric arc furnaces, however, use graphite electrodes to heat the charge through an electric arc. After melting, the molten steel in an electric arc furnace will experience an increase in carbon. Under normal circumstances, when treating high - alloy nickel - chromium steel, the minimum carbon content in an electric arc furnace is 0.06%, while an induction furnace can achieve a minimum of 0.020%. The amount of carbon added during the treatment process in an electric arc furnace is 0.020%, compared to 0.010% in an induction furnace. Non - vacuum neutral induction furnaces are thus well - suited for the treatment of low - carbon high - alloys and alloys.
The molten steel in an induction furnace has better movement conditions than that in an electric furnace. To improve the molten steel movement in an electric furnace, a low - phase electromagnetic device must be installed, but its effectiveness still falls short of that of an induction furnace. The electromagnetic stirring action in an induction furnace enhances the reaction kinetic conditions, promoting the homogenization of the molten steel's temperature and composition. However, excessive stirring can be detrimental as it is not conducive to the removal of inclusions and may even damage the furnace.
It is more convenient to control parameters such as temperature, refining time, stirring strength, and maintaining a constant temperature in an induction furnace compared to an electric arc furnace. These parameters can be adjusted at any time during the refining process in an induction furnace.
Due to the above - mentioned characteristics of induction furnaces, they play a crucial role in the treatment of high - alloy steels and alloys. They can be used independently for production or combined with secondary refining processes such as electroslag remelting and direct air consumption to form a dual - process production system. As a result, non - vacuum induction furnace treatment has become an important smelting method for producing high - speed steel, hot - work steel, stainless steel, electrothermal alloys, precision alloys, high - temperature alloys, and other special steels and alloys, and has gained widespread application.
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