A medium-frequency induction furnace (IF furnace) is a powerful tool widely used in modern metal melting and thermal processing. Known for its fast heating, high efficiency, and stable performance, it plays a central role in many foundry and metal fabrication operations. However, to fully benefit from its capabilities—and to ensure safety—operators must follow proper procedures during smelting.
In this guide, Luoyang Judian shares essential tips for safely operating your new IF induction furnace, ensuring optimal performance, longer service life, and reduced operational risks.
1. Start with Pig Iron for a Stable Melting Process
For new batches, begin smelting with pig iron. Its uniform shape and conductivity allow for better coupling with the electromagnetic field, which enhances the induced current and shortens melting time. This approach also helps stabilize the temperature rise in the early stage.
2. Proper Use of Carburizing Agents
When using a carburizer in a medium-frequency induction furnace:
- Add it gradually during the metal charge process.
- Avoid early addition, as it can sink and adhere to the furnace bottom, affecting heat transfer.
- Avoid late addition, as it may delay carbon adjustment in the molten pool and cause temperature control errors.
Controlled timing ensures accurate chemical composition and carbon recovery in the molten metal.
3. Timing the Addition of Ferrosilicon
Ferrosilicon plays a key role in adjusting the silicon content of molten iron, but timing is crucial:
- Avoid adding too early, when the metal is still solid. Premature addition may result in unwanted oxidation reactions.
- Add after partial melting, especially in furnaces with weaker electromagnetic stirring, to ensure even distribution and effective alloying.
4. Manage Metal Charge Loading Strategically
Overloading your furnace at startup can:
- Increase equipment stress
- Disrupt frequency conversion in parallel systems
- Cause inconsistent melting
To avoid this, add the charge progressively rather than all at once. This supports smoother frequency conversion and prevents overload issues during startup.
5. Control Heat-Up to Minimize Energy Loss
During the initial heat-up stage, cover the furnace to:
- Prevent surface heat loss
- Maintain temperature stability
- Accelerate the rise in molten iron temperature
This small step significantly improves thermal efficiency and maintains molten metal quality.
6. Never Add Cold Metal in the Final Melting Stage
Introducing rusty or moist pig iron into fully molten metal can lead to violent explosions and molten splash hazards. To ensure operator safety:
- Do not add charge in the late stage of melting
- Only introduce materials that are dry, preheated, and clean of surface contaminants
7. Ensure Operator Safety with PPE and Training
Every induction furnace operator should be equipped with:
- Heat-resistant gloves
- Protective clothing
- Eye and face protection
In addition to safety gear, all personnel should receive ongoing training in:
- Emergency response procedures
- Daily equipment checks
- Safe handling of molten materials
Management should enforce standardized safety practices and promote a safety-first culture on the shop floor.
Conclusion: Operate Smarter, Safer, and More Efficiently
A medium-frequency induction furnace is a valuable asset in any modern smelting operation. However, to realize its full potential, buyers and operators must follow best practices in charge loading, additive timing, and safety management. These techniques not only ensure stable furnace operation but also extend equipment life and reduce production risks.
At Luoyang Judian, we provide not only advanced induction furnace solutions, but also comprehensive guidance and after-sales support for global clients.
Contact us today to learn more about selecting and operating your next medium-frequency induction furnace.
