November 2020 Volume 2

FORGING RESEARCH AND TECHNOLOGY

Induction Power Supply and System Maintenance Cost Effective Preventative Maintenance By Joe Stambaugh, Ajax Tocco Magnethermic Corp., Warren, OH

Preventive Maintenance Helps Keep Induction Systems in Peak Condition

Dual Zone Induction Billet Heater / Photo Courtesy Ajax TOCCO

Maintenance of induction equipment can easily be ignored by assuming that everything is fine if the equipment is operating. Ignoring original equipment manufacturers' (OEM) recommended maintenance schedules can create problems that are not apparent from just looking at the system. It has long been understood that as much as 90% of induction-system problems are water related. High-conductivity water usually is the culprit that causes cooling system erosion and blockage due to electrolysis. This reaction causes the erosion of vital copper components, resulting in the collection of contaminating material, which reduces water flow. Lower water flow results in the system devices that are being cooled to overheat and fail prematurely. This is most common in water-cooling systems where high electrical potentials are present, such as silicon-carbide rectifier (SCR) and diode heat sinks and chokes (reactors). Use of lake, well, and city tap water to cool an induction power supply can reduce the service life of an induction system by 30-50%.

Electrolysis causes erosion, resulting in a hose leak failure.

FIA MAGAZINE | NOVEMBER 2020 58