Cast-In Thermal component Specifications and Tolerances

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.

 

Note: Tempco-Pak mineral insulated cable heaters can be used in place of tubular heating elements to fit physical constraints not possible with conventional heating elements. See catalog Section 5 for more details.

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.

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