Applying Ceramic Mat Heaters for Pre and Post Weld Heat Treatment

Designed for pre and post weld heat treating, ceramic mat heaters function efficiently for both curved and flat applications. The flexibility of these heaters provides a convenient means to heat treat large metal surfaces in the field.

The application of ceramic mat heaters is straightforward - the heater is placed directly on the part to be welded, insulation is normally laid over the heater, and voltage is applied. A thermocouple is tack-welded near to monitor the part. The part is brought up to temperature and then the welding is done. After the weld, the part is cooled at a controlled rate.

Welding a large pipe with localized heating using
ceramic mat heaters.

Preparing the pipe for the weld and allowing
the heaters to raise the temperature of the pipe.

Wrapping ceramic mat heaters around
spool piece.

Close-up of ceramic mat heaters around
spool piece.

Ceramic Pad/Mat Heaters: The Tried and True Way to Heat Treat

Ceramic mat heater: Proven performance over time.

Heat treating large metal surfaces in the field before and after welding is usually a challenge. Over the years, products have been developed that perform well and withstood the test of time. One of these products is the ceramic pad heater.

Ceramic pad heaters (also known as mat heaters) are constructed of interlocking sintered alumina ceramic beads (usually pink or white in color) which insulate an 80/20 Nickel/Chrome multi-strand wire (the resistance element).

Ceramic pad heaters are designed for most pre-heat and post-heat treatment requirements on weld joined materials (stress relieving). Available in numerous sizes, shapes, configurations, voltages and wattages, they can be used up to 2150°F in various weld heat treating applications.

Various shapes and sizes.

They are designed for re-use in a wide variety of heating applications. Their flexible design allows for conformance and good heat transfer to the target part. Their rugged design is well suited for most industrial environments where shock and vibration is a reality. Ceramic pad heaters can be used with or without the application of insulation. The use of insulation will greatly speed up the heating
process as well as more efficiently retain the heat for soaking.

For more information on the use and installation of ceramic pad (mat) heaters, visit Hotfoil-EHS at www.hotfoilehs.com or call 609.588.0900.

External Industrial Electric Tank Heating

Epoxy laminated panel heater installation.

If you’re looking for an excellent external tank heating solution you may want to consider epoxy laminated panel heaters (ELPs). The heaters provide a low watt density heating profile, and along with their inherent low mass,  ELPs provide excellent thermodynamic performance.

These electric heating panels use a flat foil resistive element laminated in a multi-layer fiberglass “sandwich” using epoxy resin. Manufactured under tightly controlled heat and pressure to assure bonding and structural integrity, the resulting heater is a water-proof and durable semi-flexible heating panel.

Epoxy laminated panels are used in a variety of applications, from freeze protection to process heating. They are used on either vertical or horizontal metallic or non-metallic tanks with diameters of 48" and above. They are also applied in dry or wet areas, corrosive environments, and carry FM approval for hazardous area use.

No special tools or skills are required, so they are quick and easy to install. Typically the ELPs are installed by banding them to the tank with metal bands or polyester straps, taking just a few minutes. After installation, adhesive aluminum tape should be applied to the edges of the heaters to act as a seal, preventing thermal insulation becoming trapped between the heating panels and the tank.

For more information contact:

HotfoilEHS
2960 East State Street Ext.
Hamilton, NJ 08619
Phone # 609.588.0900
Fax # 609.588.8333
www.hotfoilehs.com
Email: dap@hotfoilehs.com

240 Volt Dual Electronic Thermostat Tank Heating System Controller

The fiberglass enclosure is UL/CSA listed for use in NEMA 4, 4X, 12 and 13 environments. Employing two electronic controllers, the assembly can be used for a variety of tank and pipe heating applications requiring reliable control. Components carry UL, CSA, and CE approval with internal wiring that is NEC and IEEE compliant. The complete assembly can be provided with a UL/CUL approval stamp per customer request.

240 Volt Dual Electronic-Thermostat Tank Heating System Controller from Hotfoil EHS, Inc.

All Stainless Heat Treat Power Consoles

Hotfoil-EHS Stainless Steel Power Consoles

Power consoles are standardly offered in 6, 9, 12, 18, and 24 zone configurations with a variety of control and recording systems. All Hotfoil-EHS Power Consoles are available in Stainless Steel and can be customize to your requirements.

With decades of experience in challenging applications, and thousands of successful installations, Hotfoil-EHS maintains their well deserved reputation as the highest quality and most competitively priced manufacturer of heat treat power consoles in the world.

Freeze Protection and Temperature Maintenance for Metallic & Non-Metallic Tanks and Vessels

Hotfoil ELP heating panel construction.

With winter around the corner, manufacturing plants need to consider the possibility of freezing or low process temperatures effecting outdoor storage tanks and transfer vessels. The most common approach is to install electric heating panels on the outer surface of these tanks and vessels to prevent the contents from freezing. Lower than normal ambient temperatures can also have negative effects on the flow of liquids for a given process. In these situations it is important to maintain liquids at a constant temperature. Electric heating panels are easy to install on tanks and vessels and provide the flexibility to heat a large area of the tank surface. They can also be used to target heat to specific areas on a tank.

Typical Hotfoil ELP
heating panel placement

Hotfoil ELP heating panels are suitable for installation on metallic tanks and vessels for freeze protection or process temperature maintenance up to 79°C/175°F. They incorporate flat foil resistive elements that are laminated by heat and pressure in a multi-layer fiberglass construction with epoxy resin. The resulting electric heater design is a semi-flexible panel that is waterproof and durable. They are used in a variety of heating applications spanning from freeze protection to process heating with exposure temperatures ranging from -40 F to +212 F.

ELP heating panels can be used on either vertical or horizontal tanks with diameters of 48" and above, with either metallic or non-metallic construction.  They can be used in dry, wet, or corrosive environments, are available in 120 and 240 volts, and are approved for hazardous and non-hazardous areas.

For more information, visit www.hotfoilehs.com or call 609.588.0900

Fusion45: New Rugged Induction Heater Improves Weld Quality

New Welding Induction Heater

Heat treating isn’t done in a laboratory, or a clean room. Applications are out in the real world, where dirt, grease and grime are normal. Hotfoil’s new induction heater is designed to work in the toughest conditions, and continue to run shift after shift.

Induction heating works very quickly, and since there is no contact with the target piece, there are far less concerns about part contamination. Many industrial processes use induction heating when very high temperatures and uniform control is desired.

Pre and post-weld heat treating (stress relieving) is a growing market for induction heating systems because it offers significant benefits such as excellent heat placement and distribution, lower cycle times, safety, ease of use, and efficiency.

Induction heating can improve your bottom line by decreasing weld failures, and decreasing setup and tear down times. The technology allows for accurate temp control, without heavy electrical service or complicated controls. The portability and ease of use will allow you to heat more welds faster.

Check out the new Hotfoil-EHS Fusion45 Induction Heater:

The Hotfoil-EHS Fusion45 Induction Heater from Hotfoil EHS, Inc.