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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.

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 

 

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∆ 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.