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Metal oxide layer removal is an important part of steel processing in the automotive and mechanical engineering industry. Laser cleaning of metal oxide layer has attracted extensive attention for its selectivity and environmental protection. However, laser cleaning efficiency and high cleaning threshold remain challenges for industrial applications. To address these issues, a new electromagnetic induction heating assisted laser cleaning method is proposed. This innovative approach increases the cleaning efficiency and reduces the laser cleaning threshold via elevating surface temperature. With this novel technology, the laser cleaning threshold of metal oxide layer is reduced from 5.5 J/cm² to 3.3 J/cm². Oxygen content also decreases by 68.1% with the assistance of electromagnetic induction heating at the laser fluence of 3.3 J/cm². To validate the industrial applications of the electromagnetic heating assisted laser cleaning, a rusty steel plate is used as a sample. At the same laser fluence, the time for the rust layer reaches its evaporation temperature is shortened when assisted by the electromagnetic induction heating. The cleaning time is reduced by approximately 50% at the laser fluence of 3.3 J/cm².

This paper presents a high-frequency pulse-density-modulated (PDM) soft-switching series load resonant inverter for use in induction heating (IH) fixed roller applications, which is used in copy and printing machines. The proposed simple high-frequency resonant inverter uses an asymmetrical pulse pattern PDM control scheme to achieve complete zero-current soft-switching commutations over a wide output range of input power regulation. Additionally, when the printer toner requires operation in very light load conditions, this causes difficulty in achieving zero-voltage or zero-current soft-switching operations in the IH high-frequency resonant inverters with pulse frequency modulation or pulse width modulation control schemes. The proposed resonant inverter demonstrates the capability to accomplish highly efficient power conversions. In this work, a fixed roller for printing machines is developed for doing experiments to verify the efficiency of the proposed circuit topology and its PDM control schemes. The inverter’s steady-state and transient operating principles are analyzed based on the proposed control strategy at a high-frequency PDM. Operating conditions such as power loss analysis, power conversion efficiency and temperature rise characteristics of the proposed inverter are presented and analyzed through experimental results. Finally, from a practical viewpoint, a comparative study of a conventional halogen lamp heater and the proposed IH fixed roller is deliberated.

Induction heating technology plays a significant role in heating applications with its high efficiency, fast response, and precise control ability. Traditional resonant inverter-based systems face problems such as complexity, lack of flexibility, and low efficiency in multi-load situations. To overcome these issues, a new non-resonant full-bridge multiple-output inverter topology using silicon carbide (SiC) semiconductor devices is presented. While the system is simplified by eliminating resonant components, efficiency is increased thanks to SiC devices. In the study, a coil design methodology focusing on coil resistance and inductance is presented to optimize energy transfer and maximize system performance. Load-sensing and advanced frequency-modulation techniques are integrated to provide precise and independent power regulation in multi-loads. Thus, the efficiency of energy distribution and system robustness are increased. The proposed topology offers heating performance that provides homogeneous heat distribution. The developed prototype was proven to operate reliably with high efficiency under different load conditions and was suitably applied for domestic induction heating applications. An efficiency of 96.78% was achieved at a 50 kHz operating frequency and 2000 W power level.

The application of induction heating power supply in the continuous production line of tinplate has garnered significant research and scholarly attention. However, the impedance matching of LC or CLC resonant circuits in the system lacks flexibility and is susceptible to overvoltage during startup. As a solution to the problem, a novel four-order LCLC parallel resonant circuit was proposed in this study for high-frequency induction heating power supply. By incorporating auxiliary inductors in parallel with CLC compensating capacitor branches, the induction heating system can operate reliably and achieve optimal load impedance matching. The equivalent circuit and mathematical model of the new resonant load were established, and the frequency characteristics of the circuit system were analyzed. Then, the parallel resonance characteristics of the new resonant circuit were comprehensively elucidated, including the quality factor, impedance characteristics, behavior of resonant current, and properties of voltage regulation. Finally, a simulation model of a high-frequency induction heating power supply was developed based on the proposed LCLC resonant circuit and compared with LC and CLC resonant circuits. The results demonstrated that the induction heating power supply system utilizing the proposed LCLC parallel resonant load exhibits superior parallel resonant characteristics, enhanced load impedance-matching flexibility, and improved output voltage stability when compared to traditional LC or CLC parallel resonant loads.

Currently, we are in the research of magnetic induction heating by using conductive metal particles. The technology (comes from a phenomenon known as the “skin effect”) generates heat produced by electrical eddy currents on metal particle’s surfaces. However, till now, the power equation to describe the energy consumption of the eddy current on a single particle surface still remains ambiguous. William R. Smythe derived this equation for metal ball. A minor error was clearly located in his derivation result. Today, similar ambiguous power equation is still adopted by researchers. In order to clarify this ambiguous situation and make our further deep study on particle-based induction heating process, in this paper, I revisit the derivation of the power equation with richful results.Article highlightsTo clarify the ambiguities on the equation to describe power consumption of metal sphere under a uniform oscillating magnetic field ever found in several previous published works, the derivation for this equation is revisited, and a new equation Pr≤a is defined to study the power distribution inside a metal sphere.The value of Pa is proportional to ω when ω is very high.A power ratio equation Pδ (δ is the wave penetration depth of a conductive metal sphere) is defined, its limit is calculated: 1-e-2.

This study evaluates the influence of polymer-modification on the induction heating capability of asphalt mastic in a microwave field, and investigates how effectively this approach can be utilized for ice melting and self-healing purposes. To this end, different asphalt mastic mixtures with different polymer-modification and mixing procedures were tested under microwave field exposure for induction heating capability, ice-melting ability, and self-healing capacity. The mixtures were made through warm-mix and hot-mix procedures with four bituminous binders, including virgin (unmodified) asphalt and the same binder modified with three types of polymers. The results showed the effectiveness of microwave induction heating of asphalt mastic for both crack-healing and deicing purposes. The binder type was found to influence the ice melting and crack healing rates, such that using a warm-mix asphalt binder resulted in a more efficient heat generation and conduction than using a virgin asphalt binder. While polymer-modification undermined induction-heating, ice-melting, and self-healing performances, SBS-modified asphalt binders exhibited better performance than the other polymer-modified binders.

Induction healing technology can effectively repair microcracks in asphalt mixtures and is a promising maintenance technology for asphalt pavements. However, it requires the addition of steel wool fibers to asphalt mixtures and cannot be directly used to repair existing pavements. In order to improve the practicality of the induction healing technology, this article designs a wearing course asphalt mixture with induction healing function that is going to be paved above the existing road surface. The AC-10 asphalt wearing course for induction heating was prepared by adding steel fiber (SF). Analysis of the overall temperature of the surface revealed the unevenness of the temperature distribution, and the healing properties were investigated through protective heating that controlled the maximum temperature of the upper surface. The results show that the addition of SF can improve the high-temperature stability, low-temperature and intermediate-temperature crack resistance, and moisture stability of asphalt wearing courses; however, it has adverse effects on volumetric performance and skid resistance. The heating temperature increases with the increase in SF content, but higher maximum temperature heating rate causes worse heating uniformity and lower healing effect. The maximum heating rate of the sample with 10% SF reaches 3.92 °C/s, while its heating rate at minimum temperature is similar to that of the sample with 6% SF, which is only 0.7 °C/s, indicating the worst heating uniformity. The best healing effect occurs when the maximum temperature of the upper surface reaches 160 °C. The recommended optimal SF content is 6% of the asphalt volume. The asphalt mixture with 6% SF has an appropriate volume performance, moisture stability, and skid resistance; additionally, it has the best high-temperature stability, as well as low-temperature and intermediate-temperature crack resistance. Meanwhile, it also has uniform temperature distribution and efficient healing efficiency.

This paper proposes a shunt active filter (SAF) for harmonic mitigation and reactive power compensation in an induction heating (IH) system. The high-frequency switching in the resonant inverter of the IH system generates a considerable number of high-frequency harmonics. The latter flow back to the supply side and causes a wide variety of problems. The predominant ones are the deterioration of the power quality, distortion in the grid voltage, and malfunctioning of the protective equipment. These harmonics need to be attenuated as per the IEEE 519-1992 and IEEE 519-2014 standards. To overcome these problems, an SAF based on the modified version of instantaneous power theory was placed between the power supply and the IH equipment. Moreover, the proposed model could work in unbalanced and non-sinusoidal input voltage conditions, as well as dynamic conditions with changing reference currents. The feasibility of the proposed SAF-based IH system was verified by a series of simulation results and a comparative analysis of the THD of the input currents. The power quality issues were successfully addressed, which signifies the ability and effectiveness of the proposed model to mitigate the problems caused by harmonics and enhance the power factors.

In order to optimize the application effect of induction heating (IH) tundishes, a four-channel IH tundish is taken as the research object. Based on numerical simulation methods, the influence of different relative placement angles of induction heaters and channels on the electromagnetic field, flow field and temperature field of the tundish is investigated. We focus on comparing the magnetic flux density (B) and electromagnetic force (EMF) distribution of the channel. The results show that regardless of the relative placement angle between the heater and the channel, the distribution of B in the central circular cross-section of the channel is eccentric. When the heater rotates around channel 1 towards the bottom of the tundish, the distribution of B in the central circular cross-section of the channel changes from a horizontal eccentricity to a vertical one. Through the analysis of the B contour in the longitudinal section of the channel, the difference in effective magnetic flux density area (ΔAB) between the upper and lower parts of the channel can be obtained, thereby quantitatively analyzing the distribution of B in this section. The distribution pattern of ΔAB is consistent with the distribution pattern of the electromagnetic force in the vertical direction (FZ) of the channel centerline. The ΔAB and FZ of channel 1 gradually increase as the heater rotates downwards, while those of channel 2 reach their maximum value at a rotation angle of 60°. Compared to the conventional placement, when the heater rotation angle is 60°, the outlet flow velocities at channel 1 and channel 2 decrease by 15% and 12%, respectively. However, the outlet temperature at channel 2 increases by 1.96 K, and the molten steel flow at the outlet of channel 1 and channel 2 no longer exhibits significant downward flow. This shows that when the heater rotation angle is 60°, it has a dual advantage. On the one hand, it is helpful to reduce the erosion of the molten steel on the channel and the bottom of the discharging chamber, and on the other hand, it can more effectively exert the heating effect of the induction heater on the molten steel in the channel. This presents a new approach to enhance the application effectiveness of IH tundish.

This study introduces Internal Induction Heating (In-IH) as an efficient method for local mold temperature control in thin-walled polypropylene (PP) injection molding. Unlike conventional systems that are slow and energy-intensive, the insert is integrated directly into the induction circuit in the In-IH system, generating eddy currents for rapid and localized heating. Numerical and experimental analyses were performed to examine the effects of insert geometry and heating parameters; it was found that thinner inserts achieved higher surface temperatures—the 0.5 mm insert reached ~550 °C, while the 2.0 mm insert reached only ~80 °C—confirming an inverse relationship between thickness and temperature. Narrower inserts (25 mm) concentrated heat more effectively, whereas wider ones yielded better temperature uniformity. The cooling conditions strongly affected the temperature gradients. Mold-filling experiments demonstrated that In-IH significantly improved the flowability of PP: at 180 °C, the 0.4 mm specimen achieved a flow length of 85.33 mm, compared with 43.66 mm for the 0.2 mm specimen. At 250–300 °C, all samples approached full filling (~100 mm). The simulation and experimental results agreed, with a maximum deviation of 10%, confirming that In-IH provides rapid, energy-efficient, and precise temperature control, thus enhancing melt flow and product quality for thin-walled PP components.