Looking to make my own electric furnace, help?

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Feb 23, 2016
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Hey everyone, first time poster here. im looking to get into the scene, and it looks like heat treat is the only aspect ill need to worry about. I want to use an electric furnace due to their consistency and quality, but am unsure on exactly how to build it DIY style. My idea now is to use soft firebrick as the outer shell and machine in "trenches" to the bricks to run heating coils through. However, im not sure exactly how much coil i need to reach the temperatures i would need. Also, what ways are there to manually program / control the temperature? I imagine it would be through increasing/decreasing wattage and such, but im far from an expert.
Im working with a professor in our mechanical engineering department and have plenty of other resources to do the coding/wiring for me, i just need some way to prove i can do it with my own supplies. Any advice or plans would be appreciated!!
 
"Hey everyone, first time poster here. im looking to get into the scene, and it looks like heat treat is the only aspect ill need to worry about....." -
talk about putting the cart before the horse :) I pretty much guarantee there is a lot you need to do, get, and learn before you need a HT oven.


While it can be done, the better option is to put your efforts into learning to make knives. HT can be inexpensively done by many good providers. A HT oven isn't an autonomous device. It is only as good as the experience of the operator.

Step one - Fill out your profile and info and you may discover that there is a maker near you who will help you learn as well as do your HT.

When you have gained the experience and abilities, you can decide if you want to make an oven or buy one. Most go with buying one, as it usually ends with a better product.
 
I don't disagree with Stacy at all, but to answer your questions (somewhat):

You can get Kanthal wire, in pre-coiled lengths for different wattages, depending on how big your oven is going to be, or how fast you want it to heat up. IIRC, the length will be listed in a range, you will need to stretch the coils to separate them to a degree, so there is a little bit of flexibility there.

As for control, that's simply done with a PID and an appropriate thermocouple. You can go with a simple control, or one that can be programmed with ramping functions and whatnot.

Auberins.com is a really good resource for PIDs and the other components you'll need.

As for the grooves for the element, I just used a piece of threaded rod that was the same diameter as the element to carve the grooves in the brick. Works like a charm. Once the groove is cut, you can use a piece of rope to stick throughout the grooves and get an exact length.
 
Look for pid with
- Auto tuning
- Auto adaptation
- Smart PID / Fuzzy Logic
- Gain Scheduling
 
As pointed out above, you don't say where in the world you are. It certainly makes a difference to the electrics (Voltage, codes, etc) and availability of parts (particularly Insulating Fire Bricks with low thermal conductivity).

Analog control is almost always obtained by using a time-proportioning output from a PID controller, switching the mains power to the elements through either a contactor (big relay) or Solid State Relay. The SSR allows shorter cycles and improved control. I use a 2-second cycle because that gave the best results during my testing with fairly limited equipment. If you have the departmental resources available for testing it, you should have no problem optimizing whatever you build. Many of us would be grateful for any information you can provide if you do.

As an aside, I have tried using a true analog output from a controller to drive a phase-angle SSR (a Crydom IIRC, probably an MCPC2525C). It did not seem to control any better and was remarkably noisy with the coiled elements. I do not recommend it.

Industrial ramp/soak controllers are available and work well, but are not usually very user-friendly, particularly when setting the program steps for ramp/soak cycles: it's not usually a problem if the builder is the user, but not ideal if the user will be someone non-technical. I found that kiln controllers available at the time (about 2010) were aimed at the ceramics market and did not allow the short switching cycles that seemed to work best for HT of steels: we tend to need tight control of temperature, where ceramics are more concerned with heat-work (time at temperature).

I'd advise researching all of this very thoroughly and suggest you bear in mind that availability of complete HT ovens at reasonable prices in the USA means that the "good HT oven at a reasonable price" sector is pretty well covered there by the manufacturers: As far as I can tell from this side of the pond, most of the US DIY builds seem to be either aimed specifically at achieving the lowest possible cost, or are built as a hobby by people whose hobbies include building things like HT ovens. There may be more useful stuff on the Australian, South African and British forums where the marketplace is different but the language is (more-or-less) the same. Wiring will obviously need to meet your local code, so bear in mind the differences.

The best resource for working out your heating element requirement is the Kanthal Handbook, freely available as a .pdf online. From experience, I'd recommend using 14 AWG Kanthal A1 if you have a big enough chamber to use it and are planning on treating stainless steels ("Kanthal" is a trade name, so you could use a generic equivalent FeCrAl alloy). How long your element needs to be depends on many things, one of which is your supply voltage and another is the diameter. I'd advise 16 AWG as an absolute minimum wire size, even if you are only intending to HT Carbon steels.

Using twisted tails to get through the walls has generally proved more reliable in the long term than than using the stainless allthread shown by Andy Gascoigne in his "heat treatment furnace" pdf, but otherwise, it is a pretty good starting point and many people around the world have built to that basic design. It's worth Googling. It is dated in terms of the controls though. Electronics have moved on a lot in the decade or so since it first appeared.

Most places that can sell you the element wire can do the calculations for surface loading, resistance, length, etc and will wind the elements to suit. I did the calculation myself then checked my result against the element suppliers calculations before ordering the wound elements. Don't forget material for the staples if you are stapling the elements into the grooves.

I filed the grooves into the IFBs with allthread for my first build. Subsequent builds have had routed grooves: faster to do and tidier once done, but very very dusty at the time.
 
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