August 2026 Volume 8

EQUIPMENT & TECHNOLOGY

Figure 3: A modern Ajax TOCCO PowerZone Induction Heater utilizing IGBT devices.

Conclusion In today’s forging industry, soaring energy costs mean equipment downtime is no longer an option. The widespread adoption of IGBT-based systems reflects a critical shift toward reliable, controllable heating that supports both production goals and long term operational sustainability. Ajax TOCCO achieves this by combining advanced IGBTs with high-speed digital protection networks, delivering maximum power alongside uncompromised reliability. For modern facilities, this IGBT-driven architecture is no longer just an upgrade; it is a baseline requirement for efficiency, repeatability, and market competitiveness. Joe Stambaugh Forging Products Segment Leader Ajax TOCCO Magnethermic Phone: 614-440-0945 Email: jstambaugh@ajaxtocco.com Photos Provided by: Ajax TOCCO Magnethermic World Headquarters

• Matched Thermal Expansion (CTE): The expansion coefficient of ceramic closely matches copper and silicon, drastically reducing mechanical stress and solder fatigue during extreme temperature cycles. • High Voltage and Current Capacity: They efficiently handle high voltages (over 1000V) and large currents (hundreds of amperes) simultaneously. • Simplified Gate Drive: Being voltage-controlled, they require very little energy to switch on or off, making control circuits simpler and cheaper to design. • Electrical Isolation: Ceramics are excellent electrical insulators even at elevated temperatures, ensuring high dielectric strength. Disadvantages • Higher Manufacturing Costs: Ceramic substrates and specialized metallization processes are significantly more expensive than standard materials. • Brittle and Fragile: Ceramic boards can easily crack under excessive mechanical stress or vibration, requiring extremely careful handling during assembly and installation. • Limited Size Constraints: Ceramic substrates are generally produced in smaller panel sizes than traditional circuit boards, limiting large-format or highly expansive designs. • Slower Switching Speeds: While faster than standard BJTs, IGBTs have a "tail current" during turn-off that increases switching losses, making them less suited for ultra-high frequency (beyond a few tens of kHz) applications compared to MOSF

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16 FIA MAGAZINE | AUGUST 2026