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http://fluxtrol.com Innovations in Materials for Flux Control Presentation by Dr. Valentin Nemkov at HES 2013
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Fluxtrol Materials for Flux ControlFluxtrol Inc. produces 3 primary materials and 5 new
Primary products:• Fluxtrol A
• Fluxtrol 50
• Ferrotron 559 H
New products:• Alphaform LF, MF and HF• Fluxtrol 100 (similar to Fluxtrol A with improved
anisotropy and thermoconductivity)• Fluxtrol LF Low Frequency material
Fluxtrol Material Parameters
Properties Units Ferrotron 559H Fluxtrol 50 Fluxtrol A
Density ± 2%g/cm3 5.9 6.1 6.6
Initial 16 36 63Permeability
Maximum 18 55 120Permeability Saturation Tesla 1 1.5 1.6
Flux Density
Operating kHz 10- 10- 1-Frequency Range 3000 1000 50Temp. Resistance
Long Term Centigrade 250 250 250Short Term 300 300 300
Thermal W/cm C 0.04 0.06 0.2Conductivity
Resistivity kOhmcm >15 0.5 0.5
New Fluxtrol Material Parameters
Fluxtrol LF Alphaform LF AlphaformMF Alphaform HFProperties Units Fluxtrol 100
Densityg/cm3
6.9
6.7
4.1
4.0
3.9± 2%
Initial 80
80
11
9.8
8.8 Permeability
Maximum 130
165
13
10
9 Permeability
Saturation Tesla 1.8
1.8
1.0
1.0
1.0
FluxDensity
Operating kHz 0.05 0.05 1- 10- 20-Frequency
Range 50 3 80 450 3000
Temp. Resistance
Long Term Centigrade 200 200 225 225 225
Thermal W/cm C 0.23 0.22 0.02 0.02 0.02Conductivity
Resistivity kOhmcm 12.5 0.004 >15 >15 >15
Alphaform Materials
• Developed by Alpha 1 on the
basis of magnetic particles with
a thermal-curing epoxy binder
• Can be used for quick &
efficient results
• Material is formable when
warm
• Three versions are in
production at present time for
high (HF), middle (MF) and
low (LF) frequencies
Alphaform Application for ID Coils
Material easily fills internal volumes providing good heat
transfer to water-cooled turns.
Same inductor, one bare, the other with Alphaformshown induction heating steel pipe @ identical
power settings for 6.0 seconds.
BARE ALPHAFORM
Alphaform Application
• Main applications: - Small ID and complex geometry coils - Coils with odd turn surfaces (e.g. round tubes)- “In-house” made coils- Concentrator repair• Permeability:
Alphaform LF - 12
Alphaform MF - 10
Alphaform HF - 8• High electrical resistance• Electrical strength is 250 Vm/mm
Fluxtrol 100• Fluxtrol 100 created to substitute
Fluxtrol A• Advantages: Fluxtrol 100 has
lower anisotropy and higher thermal conductivity
• Performance of Fluxtrol 100 less dependable on cutting direction
0 50 100 150 200 250 3000
20
40
60
80
100
120
140
Fl.100 reg.
Fl. 100 perp.
Fl. A reg.
Fl. A perp.
Per
mea
bili
ty
Permeability vs. Field Strength
Field Strength, A/cm
Thermoconductivity of Fluxtrol 100:0.212 in direction of pressing0.227 in direction perpendicularto pressingThermoconductivity of Fluxtrol A:0.032 in direction of pressing0.211 in direction perpendicularto pressing
Fluxtrol 100 Application• Fluxtrol 100 has better thermoconductivity & less anisotropy
making it more fabrication friendly
Fluxtrol LF Material
• Fluxtrol LF is a new material designed for low frequency applications (up to 2-3 kHz):
- Hardening of big parts (rolls etc.)
- Seam annealing
- Tube heating
- Shielding in melting furnaces etc.
- Transverse Flux strip heating, etc.• Large volume applications are
expected, which will allow us to keep lower price
Initial permeability 80
Max permeability 160
Low losses at LF
- Material has good machinability- Thermoconductivity: 0.22 W/cmK)- Long term temperature resistance
@ 200 C, which is sufficient for LF applications (shunts, shields etc.)
- Volumetric electrical resistivity is 4 Ohmcm, which is sufficient for low frequencies
- Low electrical strength may be compensated by design measures.
Fluxtrol LF Properties
Water-Cooled Magnetic Templates
• Fluxtrol LF as well as Fluxtrol 100 may be used in multiple high temperature heating applications due to good temperature resistance and thermal conductivity
• Computer simulation can be made to find maximum temperature in water-cooled templates exposed to radiation from a hot flat body
Examples of water-cooled templatesDimensions 32.7 x 88 x 222 mm (1.3 x 3.5 x 8.8”)
Fluxtrol Gluing and Attachment• Copper & Fluxtrol surfaces should be prepared by roughing (scratching) up mating surfaces with a 50-100 grit
sandpaper• Proper epoxy selection is critical, and Fluxtrol Inc. recommends for typical applications JB Weld Epoxy Resin Part
#8265-S & 8265• A layer of epoxy should be applied to both the Fluxtrol Concentrator and the Induction Heating Coil• Clamp on even surface to secure proper positioning during cure• Remove excess epoxy for easier clean up (hot water works well)• For heavily loaded applications w/ high flux density and long duty cycles we recommend 50-3100 Epoxy Resin
(epoxies.com)• Follow manufacturers instructions for cure times• Mechanical attachment may also be used by mounting a stud or threaded boss to Induction Coil. Epoxy is still
recommended for good thermal bond efficiency
USE OF STUDS TO SECURE FLUXTROL PLATES CLAMPING FLUXTROL IN PLACE
ELECTRICAL VARNISHES
Corrosion protection Electrical insulating varnishes, paints & coatings
Electrical insulation Ceramic & nylon coatings
Antiseptic (FDA Standards) PTFE sealants for wear & chemical resistance
Impregnation Improved machinability w/ non-porous surface
Material Coatings
CERAMIC COATING PTFE COATING RESIN IMPREGNATION
Fluxtrol Machinability
1” THICK FLUXTROL 100 LOGO CUT WITH WATERJET TECHNOLOGY
CNC PRODUCED FLUXTROL 100 DETAILS FLUXTROL DETAIL W/ 1 MM WALL THICKNESS
FLUXTROL LF DETAILS MADE W/ STRD MILL TOOLS
Summary
• Soft Magnetic Composites proved to be effective materials for magnetic flux control in different induction systems due to ability to work in 3D fields, excellent machinability, good thermal conductivity and magnetic permeability sufficient for majority applications
• Different Fluxtrol materials cover the whole range of frequencies used in induction technique from 50 Hz up to 13.56 MHz