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Cast-In Band Heaters are manufactured in aluminum alloys because this material provides very good thermal conductive properties. For applications requiring higher operating temperatures and/or higher watt densities, bronze or brass alloys can be used. Cast-In Band heaters can be made with one of two cooling methods: Liquid-cooled or Air-cooled. Used heavily in plastics extrusion processes, the cooling function within our cast-in band heaters is important for maintaining the proper temperature of the barrel. Precision machining of the band heater's inside diameter yields superior heat transfer between the heater and machine barrel and is finished to customer specifications. |
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FEATURES & BENEFITS
- Toughest band available
- Can withstand almost any type of abuse without failure
- Can withstand almost any type of contamination
- Constructed of Aluminum, Brass or Bronze
- Can be produced in an almost endless variety of shapes and sizes
- Air Cooled Finned
- Liquid Cooling
SPECIFICATIONS
Operating Temp Capability 1400° F
Holes: Yes
Cutouts: Yes
Custom Delivery: 6-13 Days
Durability: Good
APPLICATIONS
Castings can be used to heat dies, extruders, chemical valves & pipelines, and also to heat & cool oil. These bands will take almost any type of abuse without failure.
- Plastics – Best choice for processing engineering grade resins
- Heating Pipes
- Chemical Processing
- Drum Heating
- Semi Conductor
- Food Process
- Packaging
If you have a special application, Cast Bands can also be modified to meet these demands. Our engineers can utilize a variety of alternative features and options to customize the heater to your specific needs.
Casting Alloys
| Casting Alloy | Aluminum | Copper | Silicone | Zinc | Lead | Maximum Iron | Tin | Other |
|---|---|---|---|---|---|---|---|---|
| Aluminum 319 | 85.8 - 91.58% | 3.0 - 4.0% | 5.50 - 6.50% | ≤ 1.0% | — | ≤ 1.0% | — | ≤1.7% |
| Aluminum 356 | 90.1 - 93.3 % | ≤0.25% | 6.50 - 7.50% | ≤0.35% | — | ≤0.60% | — | ≤1.125% |
| Bronze | 9.0 - 11.0% | ≥ 86.0% | — | — | — | 0.80 - 1.50% | — | ≤1% |
| Yellow Brass | ≤0.55% | 58.0 - 64.0% | ≤0.05% | 32.0 - 40.0% | 0.80 - 1.50% | ≤0.70% | 0.50 - 1.50% | ≤1% |
Material Properties
| Material | Classification | Max. Surface Temperature | Density | Coefficient of Linear Thermal Expansion | Specific Heat Capacity | Thermal Conductivity | Melting Point |
|---|---|---|---|---|---|---|---|
| °F (°C) | (lb/in3) | (in/in/°F × 10-6) | (BTU/lb-°F) | (BTU-in/hr-ft2-°F) | (°F) | ||
| Aluminum 319 | Aluminum 319.0 | 700 (371) | 0.101 | 12.7 @ 68° – 572°F | 0.23 | 754 | 960 – 1120 |
| Aluminum 356 | Aluminum 356.0 | 750 (399) | 0.0968 | 12.9 @ 68° – 572°F | 0.23 | 1160 | 1030 – 1140 |
| Bronze | UNS C95300 | 1350 (732) | 0.272 | 9 @ 68° – 572°F | 0.0896 | 437 | 1900 – 1913 |
| Yellow Brass | UNS C85700 | 1200 (649) | 0.304 | 12.2 @68° – 500°F | 0.0899 | 582 | 1660 – 1690 |
Minimum Casting Thickness vs. Heating Element and/or Cooling Tube Diameters
| Casting Thickness | Maximum Available Element Diameter |
Maximum Available Cooling Tube Diameter |
Maximum Element and Cooling Tube Combination |
|---|---|---|---|
| Heat Only | Cool Only | Heat and Cool | |
| 5/8" (15.9 mm) | 0.26 | 1/4 | — |
| 3/4" (19.1 mm) | 0.375 | 3/8 | — |
| 1" (25.4 mm) | 0.43 | 1/2 | — |
| 1-1/4" (31.8 mm) | 0.43 | 1/2 | .260 and 3/8 |
| 1-3/8" (34.9 mm) | 0.43 | 1/2 | .315 and 1/2 |
| 1-1/2" (38.1 mm) | 0.43 | 1/2 | .430 and 1/2 |
| 1-5/8" (41.3 mm) | 0.43 | 1/2 | .430 and 1/2 |
| 1-3/4" (44.5 mm) | 0.43 | 1/2 | .430 and 1/2 |
| Finned Casting | |||
| 3/4" (19.1 mm) | 0.375 | — | — |
| 7/8" (22.2 mm) | 0.43 | — | — |
| 1" (25.4 mm) | 0.43 | — | — |
| 1-3/4" (44.5 mm) | 0.43 | — | — |
Linear Thermal Expansion Formula:
∆ L = Li × α × (Tf - Ti) × 10-6
∆ L = Change in Length Li = Initial Length
α = Coefficient of Linear Thermal Expansion
Tf = Final Temperature
Ti = Initial Temperature
Heating Element Electrical Specifications
| Tubular Heater Diameter | .260" | .315" | .375" | .430" |
| Maximum Volts | 240 | 277 | 480 | 600 |
| Maximum Amps Per Element | 15 | 30 | 40 | 40 |
| Maximum Watt Density: | ||||
| Aluminum Alloy | 35 W/in2 on the element | |||
| Bronze or Brass | 45 W/in2 on the element | |||
| Resistance Tolerance: | +10%, −5% Wattage Tolerance: +5%, −10% | |||
| Three Phase available depending on casting size. | ||||
| Ground Studs can be added to most cast-ins. | ||||
Cooling Tube Materials for Castings with Liquid Cooling
| Tube Material | Tube OD and Wall Thickness |
|---|---|
| Stainless Steel (Standard) | 1/4" O.D. × .028 wall |
| Stainless Steel (Standard) | 3/8" O.D. × .035 wall |
| Stainless Steel (Standard) | 1/2" O.D. × .049 wall |
| Stainless Steel (Optional) | 5/8" O.D. × .049 wall |
| Incoloy® 840 (Optional) | 1/2" O.D. × .049 wall |
| Tubing with heavier wall thickness is available upon request. | |
Casting Size & Weight Limitations
| Cylindrical | Platen | |
|---|---|---|
| Minimum Inside Diameter: | 1" (25.4 mm) | — |
| Maximum Inside Diameter: | 48" (1219 mm) | — |
| Minimum Width: | — | 1-1/2" (38.1 mm) |
| Maximum Width: | — | 60" (1524 mm) |
| Minimum Length: | 1-3/4" (44.5 mm) | 4" (102 mm) |
| Maximum Length: | 40" (1016 mm) | 72" (1829 mm) |
| Finish: | 125 RMS Standard or to customer spec. | |
| Gap (two-piece cylindrical cast-in band heaters): | >1/4" (6.4 mm) top and bottom or to customer specification | |
| Maximum Weight: | ||
| Aluminum | 600 pounds | |
| Bronze & Brass | 300 pounds | |
NOTES: Cylindrical heaters are made with two half-round heaters. Cast-In thermal components can be made in any practical size, weight and geometric shape.
Options for Cast-In Thermal Components
Casting Surface Treatments Special surface finishes are required in some applications:
- Electroless Nickel Plating
- Anodizing
- Teflon®
- Hard-Coat Anodizing
- Magnaplate
Lab Services:
- Computerized Infrared Heating Profiles
- Life Cycle Testing
- X-Rays to confirm heating element location and casting density
- Heating Ramp Rate Testing
Agency Approvals:
Cast-In Heater Elements are UL recognized under UL File Number E90771.
If you require UL Agency Approval, please specify when ordering.
