Fluxtrol Resource Guide

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ResourceGuide

2006 Fluxtrol, Inc.

for Induction Technology

www.fluxtrol.com


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Section 1 Material Characteristics

Section 2 Material Selection Guidelines

Section 3 Machining

Section 4 Etching

Section 5 Application & Maintenance

Section 6 Standard Sizes

Section 7 LRM Direct LaminationReplacement Materials

Section 8 Case Stories

Section 9 Induction Basic Training

Section 10 ELTA

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Fluxtrol

Material Characteristics

1388 Atlantic BoulevardAuburn Hills, MI 48326 USA

P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277

[email protected]

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PrimaryMaterial Characteristics

A full range of products has been designed for all operating frequencies(1- 5000 kHz). Requirements for soft magnetic materials can bevery severe. Our concentrator products must perform in a very widerange of frequencies, possess high magnetic permeabilities andsaturation flux densities.

Fluxtrol concentrator materials have the following features:

Excellent thermal properties

Cover all operating frequencies used in induction

Outstanding mechanical properties

Superior corrosion resistance

Easy to machine & apply

Simple in-field adjustments

Can be used for quenchant delivery

Possibility to use as a structural component

Wide range of sizes

Properties UnitsFluxtrol

50

Product Identification Color Yellow

Fluxtrol

A

Yellow

Density 2% g/cm3 6.1

Operating Frequency Range kHz 101000

Major Frequency Area kHz 50500

Initial Permeability None 36

Maximum Permeability None 55

Saturation Flux Density Tesla 1.5

Temperature Resistance Centigrade 250Long Term300Short Term

Fluxtrol

25

Red

5.5

103000

50500

23

28

1.3

250Long Term300Short Term

Ferrotron

559H

Grey

5.9

103000

501000

16

18

1.0


Ferrotron

119

Black

4.8

105000

1001000

7

8

0.8


6.6

150

330

63

120

1.6


Physical Characteristics Chart

Primary Products Specialized Products

Green

Resistivity kOhmcm 0.5 0.5 >15 >100 >100


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Magnetic Flux Density, Gs

Fluxtrol A Permeability vs. Magnetic Flux Density

Permea

bility

0

0

40

80

120

160

3000 6000 9000 12000

Magnetic Field Strength, A/cm

Fluxtrol A Magnetic Flux Density vs. Magnetic Field Strength

MagneticFluxDensity,

Gs

0

0

2000

4000

6000

8000

10000

12000

10 20 30 40 50 60 70 80 90 100


Fluxtrol A Permeability vs. Magnetic Field Strength

Permeability

0

0

40

80

120

160

10 20 30 40 50 60 70 80 90 10

Properties Units

Product Identification Color

Density 2% g/cm3

Fluxtrol

A

Green

6.6

Initial Permeability 63

Maximum Permeability 120



Major Frequency Range kHz 330


0.2Thermal Conductivity W/cm C

Resistivity kOhmcm 0.5

FLUXTROL A

Ideal for low and medium frequency applications (1-50kHz). Highest magneticpermeability in the Fluxtrol family of soft magnetic materials. Material hasexcellent mechanical strength, thermal conductivity and good machinability.

Proper material orientation must me taken into account for heavy loadedapplications. (See Machining Section)


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Fluxtrol 50 Permeability vs. Magnetic Flux Density

Permea

bility

0

0

20

40

60

2000 4000 1000080006000


Fluxtrol 50 Magnetic Flux Density vs. Magnetic Field Strength


Gs


Fluxtrol 50 Permeability vs. Magnetic Field Strength

Permeabi

lity

0

0

20

40

60

40 80 120 160 200 240

0

0

2500

5000

7500

10000

40 80 120 160 200 240

Properties Units

Fluxtrol

50

Product Identification Color Yellow





Operating Frequency Range kHz 10-1000

Major Frequency Range kHz 50-500


Thermal Conductivity W/cm C

FLUXTROL 50

Excellent performance over a wide range of frequencies (10-1000kHz). Idealmagnetic permeability for low and medium frequency applications, yet offersthe highest permeability in the Fluxtrol family of soft magnetic materials in highfrequency applications. Material has excellent mechanical strength, machinabilityand good thermal conductivity.


0.06


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Properties Units


Density 2% g/cm3

Temperature Resistance Centigrade

Ferrotron

559 H

Grey

5.9



Saturation Flux Density Tesla 1





Resistivity kOhmcm >15


Ferrotron559H Permeability vs. Magnetic Flux Density

Permea

bility

0

0

4

8

16

12

20

1000 2000 3000 4000 5000


Ferrotron 559H Magnetic Flux Density vs. Magnetic Field Strength


Gs


Ferrotron559H Permeability vs. Magnetic Field Strength

Permeabi

lity

0

0

8

4

12

16

20

40 80 120 160 200

0

0

1000

2000

3000

4000

5000

6000

50 150100 200 250

FERROTRON 559 H

Proven concentrator material with high electrical resistivity and strength.Almost constant magnetic permeability over a range of magnetic flux densitiesand frequencies (10-3000 kHz). Material has excellent mechanical strengthand machinability.


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SpecialtyMaterial Characteristics


Fluxtrol 25 Permeability vs. Magnetic Flux Density

Permea

bility

0

0

10

20

30

2000 4000 6000


Fluxtrol 25 Magnetic Flux Density vs. Magnetic Field Strength


Gs


Fluxtrol 25 Permeability vs. Magnetic Field Strength

Permeability

0

0

10

20

30

40 80 120 160 200

0

0

2000

4000

6000

50 100 150 200

Properties Units


Density 2% g/cm3


Fluxtrol

25

Red

5.5









FLUXTROL 25

Ideal magnetic permeability for medium to high frequency applications(103000 kHz). Material has excellent mechanical strength, machinability andgood thermal conductivity.


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SpecialtyMaterial Characteristics


Ferrotron 119 Permeability vs. Magnetic Flux Density

Permea

bility

0

0

4

2

6

8

10

400 800 1200 1600 2000


Ferrotron 119 Magnetic Flux Density vs. Magnetic Field Strengt


Gs

0

0

500

1000

1500

2000

40 80 120 160 200


Ferrotron 119 Permeability vs. Magnetic Field Strength

Permea

bility

0

0

2

4

6

10

8

40 80 120 160 200

Properties Units


Density 2% g/cm3


Ferrotron

119

Black

4.8









FERROTRON 119

Material has highest electrical strength and is ideal for high, to very highfrequency applications (10 5000 kHz). Almost constant permeability over awide range of flux densities and operating frequencies. Excellent machinabilityand temperature resistance. May be used in combination with other highfrequency materials for smooth heat pattern control.


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Fluxtrol

Material SelectionGuidelines


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Notes forMaterial Selection Guidelines

The information provided below is a general reference only to cover the majorityof applications. In certain cases (heavily loaded applications, coils with smallturn to turn gaps, special cooling conditions, etc.) these guidelines may benon-optimal. For severe or special applications, please contact your Fluxtrolrepresentative or Fluxtrol directly and we will be happy to assist.

More information regarding material selection and application can be foundin Chapter 6 of the Induction Basic Training Course contained in Section 9 ofthis manual.

All material may be used at frequency lower than rated. For example Fluxtrol 50and Ferrotron 559Hhave been implemented successfully on low frequency,below 10 kHz, coils.

Concentrator Selection Guide

120

55

20

1 10 50 1000 3000

Frequency kHz

Permeabilit

y

Heav

yLoad

LowF

requency

LowLoad

HighFre

quency

FLUXTROL A

FLUXTROL 50

FERROTRON 559H


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GeneralMaterial Selection Guidelines

Coil Style Frequency Recommended Material

Single Shot

< 10 kHz Fluxtrol A

10-50 kHz Fluxtrol A or Fluxtrol 50

> 50 kHz Fluxtrol 50

Fastener / Channel All Frequencies Fluxtrol 50

Hair Pin

< 50 kHz Fluxtrol 50

> 50 kHz Ferrotron 559H

Pancake

< 50 kHz Fluxtrol 50



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GeneralMaterial Selection Guidelines

Coil Style Frequency Recommended Material

I.D. Single Turn

< 10 kHz Fluxtrol A

10-50 kHz Fluxtrol 50


I.D. Multi Turn < 50 kHz Fluxtrol 50


O.D. Cylindrical

< 10 kHz Fluxtrol A


>50 kHz Fluxtrol 50

Split & Return

< 10 kHz Fluxtrol A



>100 kHz Ferrotron 559H

Transverse Flux

< 10 kHz Fluxtrol A



>100 kHz Ferrotron 559H


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Fluxtrol

Machining


P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277

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Notes forMachining

Safety and Machining

FLUXTROL& FERROTRONflux concentrators are soft magnetic compositesconsisting of metal powders and dielectric binders compacted at highpressures with subsequent treatment.

Fluxtrol when in solid form, do not represent a fire hazard. However, the metalpowder or chips produced by machining may be a source of combustion.

The primary source of combustion is friction. Red hot chips or sparks may bethrown off, fall or drop into the collection tray of a lathe, inside a band saw ornear the grinding wheel dust. If these sparks land on accumulated machiningdust or debris, they could cause a smoldering fire. If left unattended, a firecould result.

WARNING:Do not vacuum while machining for dust collection.

Coolant is not suggested, in that it impedes the cutting process and isnot necessary.

Fluxtrol flux concentrator materials can be easily machined using common machinetools and practices (i.e., turning, milling, drilling, grinding). Use sharp tools with

slow feed and high speed.Please note that machining by theWaterJet, EDM and Laser methods are not

recommendedand Fluxtrol cannot guarantee material performance or condition ifmachined using these methods.

With respect to drilling Fluxtrol materials: the flux concentrator material may bedrilled for additional cooling, quenchant supply or mechanical attachments.When drilling pay close attention to chip removal from the drill and the hole asit is being drilled; clogged bits and or holes can result in material breakage orincorrect dimensions. Make pilot holes for large diameter holes / bores, drill ona strong support (wood/plastic block) to avoid chipping at the exit of the drill.

Threads may be cut directly in material for fasteners, but the application of insertsare recommended for heavy mechanical applications.

Fluxtrol Amay chip on sharp edges due to strong anisotropy and the machinedsurface may look different on different surface due to grain orientation.

Fluxtrol 50 and Ferrotron 559Hmay be machined into parts having sharp anglesand thin (less than 1mm) areas.


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Notes forMachining

Safety and Machining (Continued)

Anisotropy of FLUXTROL& FERROTRONmaterials:

When material has different properties in different directions they say thatmaterial is Anisotropic

Fluxtrol Ahas significant anisotropy due to its structure. In planeperpendicular to pressing direction permeability and thermal conductivity aresignificantly higher. Also, losses are lower in plane perpendicular to pressingdirection

Fluxtrol 50has lower anisotropy than A, especially inmechanical properties

Ferrotron 559Hhas much lower anisotropy due to higher content of binderand different structure

Material orientation is essential for heavily loaded applications such as scanningor single-shot hardening when concentrator losses are removed continuouslyby heat transfer to the copper. For these cases orientation Bestis stronglyrecommended with orientation N1 as a second choice. It is because the highestvalue of thermal conductivity is more important than slightly higher magneticlosses in the poles.

For short heating cycles such as contour gear hardening, orientation N2is thesecond choice after Bestbecause of lower losses in the poles than in the caseN1and lower influence of thermal conductivity on concentrator temperature.

Pressing

direction

N1 N2

Pressing

direction

Pressing

direction

N1 N2

Pressing

direction

N1 N2

Pressing

direction

Pressing

direction

N1 N2

Pressing

direction

N1 N2

Pressing

direction

Pressing

direction

N1 N2

MinMinMaxLosses

MaxMinMaxHeat transfer

(thermal conduct.)

BestN2N1

OrientationParameter

MinMinMaxLosses

MaxMinMaxHeat transfer

(thermal conduct.)

BestN2N1

OrientationParameter

Optimal Machining


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Fluxtrol

Material Etching


P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277

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Notes forMaterial Etching

Main Goal

To remove or modify conductive surface layer for better electrical resistance andelectrical strength.

Additional Possible Benefits

To prevent rusting

To improve glue or coating adhesion

Conductive layer may be formed on the part in the process of pressing ormachining due to smearing of the surface metal particles. Different materialsbehave differently in these operations.

Ferrotron 559 Hand Ferrotron 119 do not form a conductive layer in pressingor any machining operations (turning, milling, saw cutting, grinding). Etching isrecommended for electrical strength improvement and rust prevention. Electricalstrength may be important when significant external voltage applied to a thinlayer of concentrator.

Fluxtrol 25and Fluxtrol 50typically do not form conductive layers in machining

operations. However conductive layer may be formed on the side surfaces inthe process of pressing or some machining operations with dull tool, low speedand high feed. Etching is recommended for surface improvement and for higherelectrical strength when the concentrator touches coil turns with different electricpotential (non-insulated multi-turn ID coils, long hair-pin and similar coils).

Fluxtrol Aforms a conductive layer in the process of pressing and machining,especially when the machining occurs in direction of pressing (see Chapter 6Fluxtrol Materials on Induction Coils in the Training Course Basics of InductionHeating and Magnetic Flux Control). Etching is recommended for surfaceimprovement in applications where the concentrator isnt subject to external

voltage application (single-turn cylindrical coils and similar as well as coils withelectrically insulated copper). Etching is strongly recommended for concentrators,which experience application of external voltage (multi-turn coils withoutelectrical insulation of copper etc.).


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Additional Possible Benefits (Continued)

Presence of conductive layer may be identified by measuring of touch resistanceusing low-voltage ohmmeter (multimeter). If touch resistance on any surface isless than 5 kOhm, it means that there is a conductive layer.

NOTE: Never use high voltage insulation tester to measure touch resistance.High voltage (500 V and above) may break insulation between the materialparticles and form conductive channels in concentrator, permanently damagingthe material.

Etching Materials

Dont use chloric or nitric acid; they do not provide good etched surfaceand may damage material

Phosphoric acid may be used for etching and rust prevention

Fluxtrol Inc. recommends special iron-phosphoric agent CrysCoat 187,produced by Chemetall Oakite (www.oakite.com).

Etching Procedure

Parts must be clean; clean oily spots, paint and other grease using organicsolvent such as acetone

Use stainless steel, ceramic or acid resistant plastic container

For best results use 20% concentration of acid solution, i.e. 1 part ofstandard etching agent to 4 parts by volume of clean water

Place Fluxtrol parts into preheated solution (temperature 160 C = 71 F)for 15-20 min

Maintain temperature in bath at required level; a crock pot may beeffectively used for small batches of material

Use spacers between material pieces and between pieces and bath bottomfor secure contact of all the surface to solution


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Etching Procedure (Continued)

Remove parts from the solution and thoroughly rinse in clean water

Dry parts with paper towel or compressed air

Keep parts in dry room temperature area for at least 24 hours for betterresults (resistance continues to grow during this period after etching).

Concentrator Control and Spent Liquid Disposal

Chemical composition changes after etching of several material batches

The best method of etching solution control is measuring of its acidity usingPh meter such as PH 220 EXTECH Instruments

Ph factor of fresh solution must be in a range 2.8-3.5. When Ph factor goesabove 3.5, which corresponds to less acidic reaction, add more etchingagent to return Ph to required level

In the process of etching the solution color changes from light yellow todark yellow-brown and a layer of slug appears on the container bottom.Periodically clean the container

For spent liquid disposal, use standard procedure for acidic solutionsaccepted at your plant; contact manufacturer for specific instructions.

NOTE: Contact Fluxtrol Inc. at +1.248.393.2000 or [email protected] foradditional information, questions or suggestions.


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Fluxtrol

Material Application &Maintenance


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Notes forMaterial Application & Maintenance

Surface Preparation

Best FLUXTROL& FERROTRONmaterial performance may be realized whensufficient care is administered to prepare Flux Concentrator and InductionHeating Coil in the area of attachment/interface as described below:

Flux Concentrator- Clean all surfaces that are to be in intimate contact withInduction Heating Coil by removing any paint. Lightly sand with medium tomedium-fine emery paper (80-180 grit) to give adhesive a good grippingsurface. Remove any accumulated dust by wiping with a clean dry cloth or with

an organic solvent such as acetone.Induction Heating Coil- Clean all surfaces that are to be in intimate contact with

Flux Concentrator by removing any machining fluids/oils or residual quenchant.This may include sandblasting the copper surface and then wipingit with an organic solvent (such as acetone). Lightly sand with medium tomedium-fine emery paper (80-180 grit) to give epoxy adhesive a goodgripping surface. Remove any accumulated dust by wiping with a cleandry cloth.

Surface Preparation

Thoroughly Clean ALL Surfaces Indicated in Black

Flux Concentrator

Induction Heating

Coil Tubing


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Attachment of Flux Concentrator to Induction Coils

There are two main methods for attaching FLUXTROL& FERROTRON

flux concentrators to the induction coil: Adhesive and Mechanical.

For both attachment methods, flux concentrator lifetime is advanced when it is inthe best possible thermal contact with the induction coil. This can be achievedthrough the use of a uniform and thin layer of a thermally conductive mediumin-between the contact surfaces.

Adhesive Bonding

Adhesive Bonding is the most common method of attaching Fluxtrol fluxconcentrator product to an induction heating coil. Any epoxy adhesive usedmust have the following characteristics:

high temperature stability chemical resistancelow moisture absorption good thermal conductivityhigh bond strength electrically non-conductive

Care should be taken to clean all dirt, oils, greases and mechanically roughenthe contact surfaces prior to bonding. A thin layer of epoxy adhesive should be

applied to both the Fluxtrol product and induction coil copper contact surfacesand then these two surfaces are to be brought into contact and held togetherwith light pressure. Wipe away the excess glue with a damp cloth and thenfollow the curing instructions for the respective adhesive.

Adhesive Bonding

Thin Sheet between Concentrators

Induction Heating Coil Tubing

Black surfaces indicate

gap between flux

concentrator and coil filled with

thermally conductive adhesive

Flux Concentrator


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Adhesive Bonding (Continued)

For common applications, we suggest a gap or space in-between inductorcopper and Fluxtrol product of ~0.008 .012 (0.2 0.3 mm) andthe use of J-B Weld Epoxy Resin Part Nos. 8265-S & 8265(http://jbweld.net/sales/index.php#map).

For very severe environments, we recommend 503100 High Thermal K HeatTransfer Epoxy Resin (from www.epoxies.com) with a suggested gap in-betweeninductor copper and Fluxtrol product of 0.004 0.006 (0.10 0.15 mm).

NOTE: Silicone rubber is a poor thermal conductor and is recommended foruse only in lightly loaded or short duty cycle inductor coils.


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Mechanical Fastening

Mechanical Fastening is another example of how Fluxtrol flux concentrators areattached to an induction heating coil. The purpose of the mechanical fasteneris to keep the flux concentrator in place. A technique may be used where astud (i.e., screw or bolt made from brass or copper) is brazed to the inductioncoil coupled with a clearance hole drilled through the Fluxtrol product. Usewhere possible a thermal medium that is electrically non-conductive andthermally conductive i.e., heat sink paste (usually silicone based), like thoseused for mounting transistors in power supplies. Both the Fluxtrol product and

Inductor contact surfaces should be coated with a thin and uniform layer priorto fastening. After tightening down the nut on the stud, excess paste should bewiped away with a dry rag. Be careful not to over tighten the nut, as this maylead to cracking of the Fluxtrol flux concentrator. Use of plastic nuts may workto lessen the chance of cracking the concentrator.

Fluxtrol recommends using the appropriate removable thread locker such asLoctite 246high temp/medium strength thread locker for metal fasteners andLoctite 425for plastic fasteners. This will work to eliminate the possibility of themechanical fasteners loosening over time due to vibration and insure the Fluxtrolmaterial stays properly in place on the coil.

Mechanical Fastening

Thin Sheet between Concentrators

Induction Heating Coil Tubing

Black surfaces indicate

gap between flux

concentrator and coil filled with

thermally conductive adhesive

Flux Concentrator

Stud Brazed to Coil


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Maintenance of Coils with Fluxtrol Concentrators

In many applications Fluxtrol concentrators work longer than the coil copper.

Mechanical damage is one of the main factors in coil / concentrator failure andproper preventive measures must be taken.

Visual Control of Fluxtrol Concentrators:

Periodically check concentrator integrity (loose fasteners, cracks in adhesive,mechanical damage) and insulation conditions when applicable.

Periodically clean metallic chips and scale from concentrator.If Fluxtrol concentrator is seen to have a dark surface this may be due to smoke

and quenchant residue build up. Gently scratch the surface of the concentratorwith a knife or other sharp object. If material surface exposed has a grey metalliccolor and is solid, concentrator is still OK for operation.

A surface that is both dark and crumbling results from the material beingoverheated and in this case the concentrator must be replaced. If coil lifetimewas not sufficient, supply additional cooling or make coil design changes.

In some applications, especially in installations with tube generators, sparking

from the concentrator to the part or fixturing may occur. If there is groundprotection the equipment will turn off quickly however there may be small areasof the concentrator damaged by this sparking. Remove the damaged volume ofmaterial with a sharp tool and eliminate the factor that caused the sparking tooccur (too small a gap, metal particles, etc.). The concentrator can continue towork as long as the damaged area is small.


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Fluxtrol

Standard Sizes


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Standard Sizes

Listing of Standard Sizes

A wide range of standard sizes are listed below. In addition to this broadrange of standard sizes, we also have flexible manufacturing capabilitiescorresponding to your requirements for special orders (i.e., custom fluxconcentrator product formulas).

ROUNDS / BILLETS

SIZE in INCHES SIZE in METRIC mm

0.37 Dia x 2.00 (9.4 x 50.8)

0.50 Dia x 2.00 (12.7 x 50.8)0.75 Dia x 2.00 (19.0 x 50.8)1.00 Dia x 2.00 (25.4 x 50.8)1.25 Dia x 2.00 (31.7 x 76.2)1.25 Dia x 3.00 (31.7 x 76.2)1.50 Dia x 2.00 (38.1 x 50.8)1.50 Dia x 3.00 (38.1 x 76.2)1.75 Dia x 2.00 (44.5 x 50.8)1.75 Dia x 3.00 (44.5 x 76.2)2.00 Dia x 2.00 (50.8 x 50.8)2.00 Dia x 3.00 (50.8 x 76.2)2.30 Dia x 2.00 (58.4 x 50.8)2.30 Dia x 3.00 (58.4 x 76.2)

2.30 Dia x 5.12 (58.4 x 130)2.50 Dia x 2.00 (63.5 x 50.8)2.50 Dia x 2.50 (63.5 x 63.5)2.76 Dia x 2.00 (70.1 x 50.8)2.76 Dia x 2.50 (70.1 x 63.5)2.76 Dia x 3.00 (70.1 x 76.2)3.00 Dia x 1.00 (76.2 x 25.4)3.00 Dia x 2.00 (76.2 x 50.8)3.00 Dia x 3.00 (76.2 x 76.2)3.50 Dia x 1.00 (89.0 x 25.4)3.50 Dia x 2.00 (89.0 x 50.8)3.50 Dia x 2.50 (89.0 x 63.5)4.00 Dia x 1.00 (101.5 x 25.4)

4.00 Dia x 2.00 (101.5 x 50.8)4.50 Dia x 1.00 (114.3 x 25.4)4.50 Dia x 2.00 (114.3 x 50.8)5.00 Dia x 0.25 (127.0 x 6.3)5.00 Dia x 1.00 (127.0 x 25.4)5.00 Dia x 2.00 (127.0 x 50.8)6.00 Dia x 0.25 (152.4 x 6.3)6.00 Dia x 1.00 (152.4 x 25.4)6.00 Dia x 2.00 (152.4 x 50.8)6.50 Dia x 0.25 (165.1 x 6.3)6.50 Dia x 1.00 (165.1 x 25.4)6.50 Dia x 2.00 (165.1 x 50.8)


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Standard Sizes

Listing of Standard Sizes (Continued)

SMALL RECTANGULAR BLOCKSSIZE in INCHES SIZE in METRIC mm

0.25 x 1.00 x 4.00 (6.3 x 25.4 x 101.5)0.25 x 1.50 x 4.00 (6.3 x 38.1 x 101.5)0.50 x 0.50 x 4.00 (12.7 x 12.7 x 101.5)0.50 x 0.75 x 4.00 (12.7 x 19 x 101.5)

0.50 x 1.00 x 4.00 (12.7 x 25.4 x 101.5)0.50 x 1.50 x 4.00 (12.7 x 38.1 x 101.5)0.50 x 2.00 x 4.00 (12.7 x 50.8 x 101.5)0.63 x 0.63 x 4.00 (16 x 16 x 101.5)0.63 x 0.75 x 4.00 (16 x 19 x 101.5)0.63 x 1.00 x 4.00 (16 x 25.4 x 101.5)0.63 x 2.00 x 4.00 (16 x 50.8 x 101.5)0.75 x 0.75 x 4.00 (19 x 19 x 101.5)0.75 x 1.00 x 4.00 (19 x 25.4 x 101.5)0.75 x 1.50 x 4.00 (19 x 38.1 x 101.5)0.75 x 2.00 x 4.00 (19 x 50.8 x 101.5)1.00 x 1.00 x 2.00 (25.4 x 25.4 x 50.8)

1.00 x 1.00 x 3.00 (25.4 x 25.4 x 76.2)1.00 x 1.00 x 4.00 (25.4 x 25.4 x 101.5)1.00 x 1.25 x 4.00 (25.4 x 31.7 x 101.5)1.00 x 1.50 x 3.00 (25.4 x 38.1 x 76.2)1.00 x 1.50 x 4.00 (25.4 x 38.1 x 101.5)1.00 x 2.00 x 4.00 (25.4 x 50.8 x 101.5)


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Standard Sizes

Listing of Standard Sizes (Continued)

LARGE RECTANGULAR BLOCKSSIZE in INCHES SIZE in METRIC mm

0.25 x 4.00 x 7.75 (6.3 x 101.5 x 197)0.50 x 4.00 x 7.75 (12.7 x 101.5 x 197)0.63 x 4.00 x 7.75 (16.0 x 101.5 x 197)0.75 x 4.00 x 7.75 (19.0 x 101.5 x 197)1.00 x 4.00 x 7.75 (25.4 x 101.5 x 197)

0.38 x 6.12 x 8.12 (9.6 x 156 x 206)0.50 x 6.12 x 8.12 (12.7 x 156 x 206)0.75 x 6.12 x 8.12 (19.0 x 156 x 206)1.00 x 6.12 x 8.12 (25.4 x 156 x 206)0.38 x 3.00 x 8.12 (9.6 x 76 x 206)0.50 x 3.00 x 8.12 (12.7 x 76 x 206)0.75 x 3.00 x 8.12 (19.0 x 76 x 206)1.00 x 3.00 x 8.12 (25.4 x 76 x 206)0.38 x 4.00 x 6.12 (9.6 x 102 x 156)0.50 x 4.00 x 6.12 (12.7 x 102 x 156)

0.75 x 4.00 x 6.12 (19.0 x 102 x 156)1.00 x 4.00 x 6.12 (25.4 x 102 x 156)

For price and delivery information and also for custom sizes and/or machinedparts, please contact Fluxtrol at 248-393-2000 / 800-224-5522

[email protected]


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Fluxtrol LRM

Direct LaminationReplacement


P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277

[email protected]

2008 Fluxtrol,


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2008 Fluxtrol,

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Fluxtrol Direct Lamination Replacement

Using Fluxtrol greatly reduces the labor intensive task of stacking and attachinglaminations individually. All FLUXTROL& FERROTRONmaterials, beingsolid in form, eliminate the degradation/corrosion build up that is commonbetween individual laminations. Lamination degradation can result in coil failureor changes to the heat pattern. Another significant benefit of FLUXTROL&FERROTRONmaterials is that they can be easily machined. This includes in-fieldmodification when necessary which is not possible with individual laminations.

Induction Coils Perform Better

Improved coil lifetime withFluxtrol LRM versus laminationsdue to reduced copper thermalracheting.

No overheating in the presenceof 3D magnetic fields.

Fluxtrol LRM covers more of theinductor for greater efficiency.

Fluxtrol LRM can be positionedwithout keepers for enhancedheat pattern control.

FluxtrolLRM Benefits

Cost effective alternative tolaminations with fast delivery.

Less construction time versuslaminations.

Available in near-net shapesand finished to size.

Copper operates at lowertemperatures with Fluxtrol LRMversus laminations.

FLUXTROL The Ultimate Lamination Replacement Material for Your Next Coil!


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Fluxtrol Lamination Replacement Material (LRM)

Fluxtrol LRM utilizes the anisotropic nature of the magneticcomposite material to maximize flux concentrator andinduction coil performance

Optimal orientation of material in C-shaped concentratorprovides high permeability, lower losses and:

Magnetic and thermal properties are higherin the direction perpendicular to pressing.

Electrical strength is higher in direction of pressing

Induction Coil Runs Cooler with FluxtrolLRM

Steady state temperature distribution inthe in pipe seam anneal induction coilwith Fluxtrol LRM Temperature scale 20 250 C

Temperature Evolution Curves in Critical Areas for Intermittent Heating

Maximum coppertemperature with

Fluxtrol LRM is 20 C lessthan with Laminations,temperature variation spanis 35 C lower

Laminations FluxtrolLRM


F Pressure Direction B Flux DensityP Heat Transfer

Steady state temperature distribution inthe in pipe seam anneal induction coilwith laminations Temperature scale 20 250 C


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Comparison of Laminates versus FluxtrolLRM

Fluxtrol LRM (right) has equivalentheating to laminations (left)

Lamination Fluxtrol LRM

Typical Failure Mode of Laminations Crankshaft Coil Failure

Copper Coil Crack


Image illustrates lamination overheating ina three dimensional field (blue edges)

Copper failure due to thermal rachetingon crankshaft coil with lamination

Comparison of Lifetime Improvement with FluxtrolLRM

Coil Lifetime with Fluxtrol LRM was2.3 times longer than coil laminationsover an 18 month period.

Lamination

Fluxtrol LRM

Fluxtrol LRM


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Fluxtrol Material Properties

FLUXTROLLRM

Ideal for low and medium frequency applications (.0530kHz). Highest magneticpermeability in the Fluxtrol LRM family of materials. Material has excellentmechanical strength, thermal conductivity and good machinability.


Fluxtrol LRM Permeability vs. Magnetic Flux Density

P

ermea

bility

0

0

40

80

120

160

3000 6000 9000 12000


Fluxtrol LRM Magnetic Flux Density vs. Magnetic Field Strengt


Gs

0

0

2000

4000

6000

8000

10000

12000

10 20 30 40 50 60 70 80 90 100


Fluxtrol LRM Permeability vs. Magnetic Field Strength

Permeab

ility

0

0

40

80

120

160

10 20 30 40 50 60 70 80 90 100

Properties Units

Density 2% g/cm3

Fluxtrol

LRM

6.6




Operating Frequency Range kHz .0530

Temperature Resistance Centigrade 250 Long Term300 Short Term




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Fluxtrol Material Properties (Continued)

FLUXTROLLRM Medium Frequency

Excellent performance over a wide range of frequencies (10-500kHz). Idealmagnetic permeability for low and medium frequency applications, yet offersthe highest resistivity in the Fluxtrol LRM family of materials in medium frequencyapplications. Material has excellent mechanical strength, machinability andgood thermal conductivity.


Permea

bility

0

0

20

40

60

2000 4000 1000080006000


Fluxtrol LRM MF Magnetic Flux Density vs. Magnetic Field Streng


Gs


Fluxtrol LRM MF Permeability vs. Magnetic Field Strength

Fluxtrol LRM MF Permeability vs. Magnetic Flux Density

Permea

bility

0

0

20

40

60

40 80 120 160 200 240

0

0

2500

5000

7500

10000

40 80 120 160 200 240

Properties UnitsFluxtrol

LRM MF










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Standard Lamination Replacement Sizes

NOTE:If your application requires

sizes/dimensions different than thoseshown, please contact Fluxtrol

as custom sizes can be produced.

248-393-2000 / 800-224-5522

[email protected]

1.000

(25.4)

1.000

(25.4)

2.00

(50.8)

0.375

(9.52)

0.375

(9.52)1.357

(34.5)

1.764

(44.8)

0.764

(19.4)

0.757

(19.2)

2.00

(50.8)

1.000

(25.4)

1.375

(34.9)

2.00

(50.8)

0.625

(15.9)

0.625

(15.9)

FluxtrolLRM is Designed for:

Axle Bar coils

Crankshaft coils

Stem coils

Spindle & Bearing coils

Seam Anneal coils

Specialty Melting coils

FluxtrolLRM Application Methods

Thermally conductive two partepoxy is recommended.

In addition, the following mechanicalfasteners may be employed.

Secured by copper tabs

Brass studs with washers and nuts Drawn together with flexible

bands

Trapped in place with non-conductive materials

FluxtrolLRM is Aggressively Priced to Replace Laminations!



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Fluxtrol

Case Stories


P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277

[email protected]

2008 Fluxtrol,


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2008 Fluxtrol,

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Making the CaseSuccess with Using Fluxtrol

Application: Aluminum Brazing of Heat Exchanger

Original Concentrator: Ferrotron 559H

Problem / Failure Mode: Cold Joints, Leaking Joints, Localized Overheating

Power Supply: 60 kW (30 kW in use), 1025 kHz, (1215 kHz in use)

Problem / Solution: Customer experiencing long cycle times & poor quality

Fluxtrol Achosen as concentrator

Condition simulated using computer simulation

Optimized coil design via computer simulation

New coil design utilizing Fluxtrol Abuilt and tested

Tests meet spec and new coil put into production

Fluxtrol Advantage: No Quality Issues & 30% Cycle Time Reduction!


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Application: Fastener Heat Treating / Channel Coil

Original Concentrator: None

Problem / Failure Mode: Insufficient Production Rate

Power Supply: 25 kW (15 kW in use), 150 400 kHz (200 kHz in use)

Problem / Solution: Customer not satisfied with cycle timesPower supply at current limitCustomer need to increase production w/limited expense

Application evaluated and Fluxtrol 50selected

No other changes were made other thanadding Fluxtrol 50

Tests meet spec and coil returned to production

Fluxtrol Advantage: Production Rate Increased 100%!


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Application: Automotive Camshaft / Static Hardening Coil


Problem / Failure Mode: Unsatisfactory Cycle Times & Poor Heat Pattern Control

Power Supply: 100 kW (70 kW in use), 10 kHz, (8 kHz in use)

Problem / Solution: Customer not satisfied with cycle times and back tempering of adjacent lobe Application evaluated and Fluxtrol Aselected

No other changes were made other thanadding Fluxtrol A


Fluxtrol Advantage: Cycle Time Reduced 26%, Power Reduced 30% andNo Back Tempering of Adjacent Lobes!


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Application: Geared Tractor Hub / Simple O.D. Coil w/Integral Quench


Problem / Failure Mode: Long cycle times and poor heat pattern control

Power Supply: 50 kW (22 kW in use), 10 kHz

Problem / Solution: Customer not satisfied with cycle timeCustomer experiencing high scrap rates

Application evaluated and Fluxtrol AselectedNo other changes were made other than addingFluxtrol AFluxtrol applied per supplied guidelines


Fluxtrol Advantage: Cycle Time Reduced 42%, Positive Control of Heat Pattern!


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Application: Case Harden S-Cam and Shaft


Problem / Failure Mode: Extended Cycle Times / Loss of Pattern Control

Power Supply: 150 kW (135 kW in use), 310 kHz (7 kHz in use)

Problem / Solution: Customer not satisfied with cycle timesCustomer experiencing loss of pattern control

Coil and application reviewed for pattern and timeOptimized coil design via computer simulation

New coil design utilizes Fluxtrol Amaterial Tests meet spec and coil returned to production

Fluxtrol Advantage: Cycle Time Reduced 46% with Pattern Improvement!


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2008 Fluxtrol,

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Lamination Replacement

Application: Case Harden Wheel Hub with Single Bearing Race

Original Concentrator: Silicon Steel Laminations

Problem / Failure Mode: Short Coil Life / Copper Failure of 2 Half Turns Copper

Power Supply: 150 kW ( 100 kW in use), 1025 kHz (15 kHz in Actual Use)

Problem / Solution: Customer experiencing life of 8,000 to 13,000 cyclesLaminations replaced with Fluxtrol A, no other changes

Lifetime increased to 15,000 to 20,000 cyclesOptimized coil design via computer simulation

New coil design utilizes Fluxtrol 50material Tests meet spec and coil returned to production

Fluxtrol Advantage: Coil Life Extended to >150,000 Cycles!


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Lamination Replacement

Application: Case Harden Shaft by Rotating in Static Position

Original Concentrator: Silicon Steel Laminations

Problem / Failure Mode: Short Coil Life / Corrosion & Overheating of Laminations

Power Supply: 600 kW (450 kW in use), 310 kHz (9 kHz in Actual Use)

Problem / Solution: Customer not satisfied with life of 150,000 cyclesFluxtrol given opportunity to replace laminations

Application evaluated and Fluxtrol 50chosenNo other changes were made other than Fluxtrol 50

Laminations removed and replaced with Fluxtrol 50 Tests meet spec and coil returned to production

Fluxtrol Advantage: Coil Life Extended to >300,000 Cycles!


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Fluxtrol

Induction Basic Training


P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277

[email protected]

2008 Fluxtrol,


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2008 Fluxtrol,

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InductionBasic Training

Introduction

This Training Course is developed for people with different technical levels(technology users, designers, coil manufacturers, businessmen etc.) for betterunderstanding of:

How induction heating works

Equipment used for induction heating applications

How to design optimal processes and induction coils usingcomputer simulation

The benefits of using magnetic flux controllers (concentrators)

Proper concentrator material selection and fabrication

The application of Fluxtrol controllers to induction coils

What results have been achieved in selected applications (case stories)

It is not possible to describe in a short course all the features and numerousapplications of induction heating. The main emphasis of this course is placedon the theory, understanding and practice of magnetic flux control in inductionheating systems.


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InductionBasic Training

Software Version, Compatibility

This Training Course was created using Microsoft Office Professional /PowerPoint 2003

This presentation has been tested on PowerPoint 97 and later and will workon those older versions with only minor picture quality degradation

If you have difficulty in opening the files on the Basic Training CD pleasecontact Fluxtrol, Inc. (248-393-2000) so we can assist you by providing aversion that is compatible with your computer.


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ELTA

Simulation Software


P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277

[email protected]

2008 Fluxtrol,


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2008 Fluxtrol,

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ELTASoftware

ELTA Software

ELTA is a program for ELectroThermal Analysis of induction systems

Calculations in ELTAare based on a combination of 1D Finite ElementMethod for closely coupled electromagnetic and thermal problems insidethe work piece and analytical method for account of finite lengths of thepart and induction coil. Special 2D numerical method is used for calculationof parameters inside parts with rectangular cross-section.

ELTA Software Features User friendly interface with very fast solver

Electromagnetic + Thermal

Axisymmetrical (OD & ID) & plane-parallel geometries

Module for simulating single- and multi-turn internal coils

Possibility to simulate power supplying circuit (busswork, parallel or seriescapacitors, matching transformer)

Possibility to simulate multi-stage processes such as part hardening andtempering in different positions

Database with non-linear properties of materials and quenching media

Option of automatic frequency variation during the process of heating

Multiple graphs and color map for presentation of the results

Automatic report generation according to selected or createdby user templates


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ELTASoftware

When to Use ELTA

ELTAmay be used for design of the whole system (heating time, frequency,power, coil parameters, selection of power supplying circuitry) or asan auxiliary tool for design of systems with complex geometry. Finalinduction system optimization may be made using 2D (3D) program orexperimentally. ELTAis also an important tool for education, training andbusiness presentations.

It is:

Valuable for almost all cases to determine optimal process parameters(P, f, t, Quenching) and coil style

A useful tool for coil design in both static and scanning applications

Very valuable for in-field support, new project evaluation and presentations

Mass heating of billets and tubes in single-ormulti-inductor lines

Heating of Slabs and strips in single- ormulti-inductor lines


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ELTASoftware

When to Use ELTA (Continued)

Local heating and surface hardening ofcylindrical or flat bodies

Scan hardening of cylindrical parts

Scan hardening of flat surfaces


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ELTASoftware

Using ELTA Software Screen Examples

Screen of Supplying Circuitry

Screen of induction coil

Screen of workpiece geometry description


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ELTASoftware

Design of In-Line Heat Treating Process

In-Line processes are becoming more popular in industry. In these processesdurations of all stages of in-line process (Austenization, Quenching, Temperingand Final Cooling) must be coordinated

Task: Hardening and tempering of the shaft end

Diameter 40 mm

End length 60 mm

Case depth 4 mm

Steel 1040

Simulation showed that minimum time for austenization, heating is slightlyunder 4 sec. at optimal frequency 3kHz. This time was selected as a basefor other stages:

Austenization 4sec

Quenching 8 sec

Tempering 4 + 4 sec

Final cooling 8 sec

Induction System Geometry


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ELTASoftware

Design of In-Line Heat Treating Process (Continued)

Rotary table machine with 8 positions was selected for heat treating.Two positions were used for tempering.

Color Map of temperature distribution shows that at the end of the first stage adepth of austenitized layer (T> 800 C) is 4 mm as required.

After 8-second quenching, temperature at the depth of 4 mm dropped below120 C, which is sufficient for complete martensite transformation, whiletemperature at the center remained around 300 C.

This residual temperature and two-stage heating for tempering provided veryuniform temperature in hardened layer during tempering process.

Rotary Table Cycle Diagram

Color Map of Temperature DistributionTemperature evolution in optimized process:

Green part surfaceRed centerBlack temperature differential

Load/Unload

Austenitizing

Quenching

Tempering

Cooling


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ELTASoftware

Design of In-Line Heat Treating Process (Continued)

3D presentation of temperature evolution

Cooling curves at different distances from surface


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ELTASoftware

Report Automatically Generated by ELTA


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ELTASoftware

Demonstration Example of Scanning Process Designed with ELTA

Industrial robot moves hairpin inductor along the curved surface of water-cooledstand made of stainless steel.

Fluxtrol concentrator is installed on one half of the coil. There is almost no heatingunder the coil part without concentrator.

Example of hairpin Inductor with concentrator on one half of coil

Temperature distribution was accurately predicted by the ELTAprogram.


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Documents

Fluxtrol Resource Guide