The bursting of a cartridge heater refers to the rupture of the metal outer wall of the cartridge heater after power is applied. This damage is irreversible and must be avoided at all costs.
After extensive investigation and data collection, we have attempted to analyze the causes of cartridge heater bursting:
1. Design issues. If the power design of the cartridge heater is too high, the internal temperature rises rapidly and reaches high levels, causing internal expansion of cartridge heater. The surface load on the metal outer heater becomes too great, ultimately leading to expansion and cracking of the heater.
2. Material issues – the metal heater itself. Poor quality tube material, excessively thin tube walls, or insufficient temperature resistance of the material itself can all lead to insufficient pressure resistance of the tube.
3. Material issues – magnesium oxide powder. Magnesium oxide powder, used as a heat conducting and insulating material, is distributed between the heating wire and the heating tube wall. It is one of the most important materials in the cartridge heater. Insufficient purity, excessive impurities, or moisture in the magnesium oxide powder can easily cause heat to accumulate in a certain location within the tube, preventing heat dissipation. When this reaches a certain limit, it can cause the tube to burst.
4. Manufacturing Defect – Poor Sealing. The heating element's seal was improperly applied, leading to internal moisture ingress. When high voltage and current pass through, this causes a short circuit and breakdown, resulting in tube rupture.
5. Manufacturing Defect – Tube Diameter Processing Issues. This applies only to heating elements used in mold heating. When the gap between the heating element and the mold hole is too large, heat cannot be effectively transferred to the mold, essentially causing continuous dry heating, which is very dangerous.
6. Usage Problems – Damage to the tube wall from impacts, improper storage, using a voltage far exceeding the rated voltage, and incorrect wiring are also common causes.
7. Usage Problems – Excessive Liquid Impurities. This applies only to heating elements used for liquid heating. When there are excessive impurities in the liquid, these impurities will adhere to the surface of the heating element (such as scale), preventing localized heat transfer and causing tube rupture.
So, how can we prevent electric heating elements from bursting?
1. Product design issues, material issues, and manufacturing process issues are beyond the user's control. However, users can choose qualified and experienced electric heating element manufacturers, entrusting these problems to professional teams to address these "invisible" issues.
2. Use the heating element strictly according to the rated voltage and correct wiring method. Store it in a dry place. For cartridge heaters that have not been used for a long time, start with a low voltage and gradually increase the operating voltage.
3. For cartridge heaters used for liquid heating, improve water quality to reduce impurities, or regularly clean the surface of the heating tube.
4. Heating tubes are consumable products. Users should regularly inspect for potential hazards, and perform regular maintenance and replacement of the core heater components.
