There are 2 updated Hotfoil-EHS catalogs available for download now.
A revised and updated Hotfoil product catalog can be downloaded here. It includes information about Type HB Hopper Heating Modules,Type FRP Heating Panels, Type ELP Heating Panels,Type GA Heating Blankets, Type HSR / HSRX Silicone Rubber Heaters, Type PCW and SRC Heating Cable, Type MI Metal Sheathed Heating Cable, Tank Heating Controls, Hopper and Chute Heater Controls, and Heat Control Systems for Hazardous Areas.
A revised and updated EHS product catalog can be downloaded here. It includes information about Power Consoles, Fusion 45 Induction Console, Ice Star Heat Treatment Control System, Ceramic Mat Heaters, Rope Heaters, 4-Banks and Accessories, Temperature Recorders, Pinwelders & Thermocouple Attachment Units and Accessories, Brinell Tester & Poldi Hardness Testers, Triple Cable Sets, Splitters, Insulation and Accessories, T/C Wire, Banding, Twistlocks and Accessories, EHS Gas Trains, Furnace Fabrication & Capabilities, and Custom Generator Trucks / Mobile Heat Treatment.
For more information, contact Hotfoil-EHS by calling 609-588-0900 or visiting their web site at https://hotfoilehs.com.
A blog that provides educational information on electric heating systems used on hoppers, chutes, tanks and vessels; electric heating systems used for pre and post weld heat treating; heat treating power consoles; custom heat treating furnaces; and single & multi-operator welders. For more information, visit HotfoilEHS.com
Showing posts with label Ceramic Mat Heaters. Show all posts
Showing posts with label Ceramic Mat Heaters. Show all posts
New Hotfoil-EHS UK Ltd. Product Brochure
Hotfoil-EHS UK has just released a new general product capability brochure. You can download the PDF here.
Pre Weld and Post Weld Heat Treatment
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Welding between insulated heating areas Heating done by ceramic heaters (pink). |
An industry standard means of accurately managing the pre-heat and post-weld heat treatment is through the use of specialized electric heaters. Electric welding preheaters, known as "ceramic mat heaters", are rugged and flexible heating elements designed so that they conform uniformly around the weld and surrounding area. Ceramic mat heaters are normally controlled by a power console that uses thermocouples and electronic controllers to regulate, monitor, and many times record, the preheat temperature profile.
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Ceramic heaters on spool piece. |
Before deciding to preheat or post heat any welding job, consult with a heat treating expert to make sure proper welding code requirements are being followed.
Ceramic Pre Weld and Post Weld Heaters Get The Heat to the Weldment Efficiently
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Ceramic mat heaters |
Design:
1) Sintered alumina oxide is formed into shapes and fired at precise temperatures to produce a ceramic insulator with a combination of high dielectric strength and efficient, fast heat transfer. This ceramic is also solid enough to withstand physical shock and resistance to oxidation and corrosion from a broad range of chemicals and atmospheres.
2) An accurately measured length of stranded nickel-chromium wire is precisely wound through the ceramic beads ensuring electrical isolation to produce a compact and flexible resistance heater. Suitable for operation at 2000 deg. F.
3) The resistance wire is then metallurgically bonded to a stranded nickel-copper wire to provide trouble free electrical continuity. The flexible stranded cold junction wire is connected to brass Twistlock connectors fitted with insulated sleeves. The cold junction extension leads are rated for 250 deg. C continuous temperature.
Ceramic mat heaters are efficient, time-tested, and proven heater technology in pre-weld and post weld heating, and are designed for the harsh realities of the welding environment.
For more information, contact:
Hotfoil-EHS, Inc.
2960 East State Street Ext.
Hamilton, NJ 08619
Phone # 609.588.0900
Fax # 609.588.8333
www.hotfoilehs.com
Ceramic Heater Pads for Weld Preheating and Post Weld Heat Treating
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Welding ceramic pad heater (courtesy of HotfoilEHS) |
It is very important to understand the material characteristics of the metals being welded, and know minimum and maximum preheat temperatures, particularly in tempered steels.
For most preheating, post heat treating, and interpass heating, precise temperature control isn't required. Its more important to maintain a minimum temperature, and stay within an acceptable range during the actual welding process, as well as during cool down.
Exceptions are with tempered steels. Tempered steels have already been heat treated at the steel mill and applying too much preheat can alter that tempering. In these cases, proper set point, temperature limiting, and temperature ramp rate of the welded part is critical.
Use of Ceramic Heater Pads
Resistance heating pads are constructed of ceramic beads strung on nichrome wire. These resistance heating elements accurately raise the workpiece temperature to the proper temperature before, during, and after welding, complying with recommended preheat, interpass, and PWHT practices. These semi-flexible ceramic heater pads, with their interlocking beads and high temperature wire, allow for a fit conforming to the shape of the workpiece, and are capable of temperatures up to 1,850 degrees F. Ceramic mat (pad) heaters have an additional benefit in that they don’t have to be moved during welding.
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Recorders and controls used for welding preheat and post heat. |
An average application is as follows: the heater pad is wrapped around the workpiece, and insulation is applied to the weld joint and the temperature controller is set. Once preheat temperature is achieved, a welder removes the insulation and starts their work. After the weld, the ceramic heaters can be placed over the weld and the controllers can be reset for proper PWHT.
Automatic Heat Treatment Power Consoles
Typical Power Console (courtesy of HotfoilEHS) |
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Ceramic Mat Heater |
Thermocouples are used to sense the target temperature and send their signal back to some type of electronic temperature controller, recorder, or combination thereof. The sophistication of the control system can range from simple manual control to fully automatic control with large graphic displays. Recorders are frequently used to document the pre-heat, soak, and post-heat process. Welding integrity depends on precise and accurate control.
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Recorder used on welding power console. |
For more information, contact:
Hotfoil-EHS, Inc.
2960 East State Street Ext.
Hamilton, NJ 08619
Phone # 609.588.0900
Fax # 609.588.8333
www.hotfoilehs.com
Email: dap@hotfoilehs.com
Ceramic Mat Heaters for Pre & Post Weld Heat Treating
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Ceramic mat heater for pre and post weld heat treatment. |
It's very important to pre-heat metal to a specific temperature prior to welding. Pre-heating metals reduces stress in the finished weld, as well as eliminates moisture and improves the metallic microstructure of the weld material. For post weld heat treatment (PWHT), use of resistance heaters to apply carefully controlled cool-down can significantly increase the cross-weld toughness of the heat-affected zone.
Ceramic mat heaters are manufactured using high grade nickel chrome (NiCr) 80/20 wire insulated with interlocking sintered alumina ceramic beads, providing flexibility and convenience for use on curved or flat surfaces. Their design also allows for good contact and high heat transfer. Ceramic mat heaters are intended for repeated use and have considerable mechanical strength and durability. They are capable of achieving temperatures of up to 2050°F. and are most often are supplied with ceramic insulated leads with either Camlock or Dinse type welder terminations.
The most common voltages used are 40, 60, and 80 volts (as supplied by arc welders) but many custom voltages are available. Special sizes, heating patterns and terminations are also easily accommodated with ceramic mat heaters.
For more information, contact:
Hotfoil-EHS, Inc.
2960 East State Street Ext.
Hamilton, NJ 08619
Phone # 609.588.0900
Fax # 609.588.8333
Email: dap@hotfoilehs.com
Hotfoil-EHS, Inc.
2960 East State Street Ext.
Hamilton, NJ 08619
Phone # 609.588.0900
Fax # 609.588.8333
Email: dap@hotfoilehs.com
Welcome to Our Industrial Heating, Welding and Weld Pre-heating Blog
Hotfoil-EHS is committed to educating and training users of our products, namely electric hopper heating systems, electric pre and post weld heat treating, heat treating furnaces, and multi-operator welding stations.
In future posts, we hope to provide interesting information for a wide variety of applications, performance, and products for the markets we serve.
Here is a breakdown of those markets and products:
HOTFOIL
Coal and Fly Ash Hopper Heaters, Industrial Tank Heaters, Heating Cable, Silicone Heater Blankets, Control Systems.
EHS
Pre & Post Weld Heat Treating Power Consoles, Ceramic Mat Heaters, TAU Units, Temperature Recorders, Cable Sets, Brinell Testers.
AFTEK-EHS
Multi-Operator Power Supplies, Packaged Welding Systems, Single Operator Welders, GRID Systems, Custom Transformers.
In future posts, we hope to provide interesting information for a wide variety of applications, performance, and products for the markets we serve.
Here is a breakdown of those markets and products:
HOTFOIL
Coal and Fly Ash Hopper Heaters, Industrial Tank Heaters, Heating Cable, Silicone Heater Blankets, Control Systems.
EHS
Pre & Post Weld Heat Treating Power Consoles, Ceramic Mat Heaters, TAU Units, Temperature Recorders, Cable Sets, Brinell Testers.
AFTEK-EHS
Multi-Operator Power Supplies, Packaged Welding Systems, Single Operator Welders, GRID Systems, Custom Transformers.
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