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Resource

Guide

for Induction Technology


2006 Fluxtrol, Inc.

2008 Fluxtrol, Inc.


www.fluxtrol.com

www.fluxtrol.com

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 Lamination
Replacement Materials
Section 8 Case Stories
Section 9 Induction Basic Training
Section 10 ELTA

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol

Material Characteristics

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

Primary
Material Characteristics

A full range of products has been designed for all operating frequencies
(1- 5000 kHz). Requirements for soft magnetic materials can be
very severe. Our concentrator products must perform in a very wide
range of frequencies, possess high magnetic permeabilities and
saturation 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
Physical Characteristics Chart
Primary Products

Specialized Products

Fluxtrol
A

Fluxtrol
50

Ferrotron
559H

Fluxtrol
25

Ferrotron
119

Yellow
Green

Yellow

Grey

Red

Black

g/cm3

6.6

6.1

5.9

5.5

4.8

Operating Frequency Range

kHz

150

101000

103000

103000

105000

Major Frequency Area

kHz

330

50500

501000

50500

1001000

Initial Permeability

None

63

36

16

23

Maximum Permeability

None

120

55

18

28

Saturation Flux Density

Tesla

1.6

1.5

1.0

1.3

0.8

Temperature Resistance

Centigrade

250 Long Term


300 Short Term

250 Long Term


300 Short Term

250 Long Term


300 Short Term

250 Long Term


300 Short Term

250 Long Term


300 Short Term

kOhmcm

0.5

0.5

>15

>100

>100

Properties

Units

Product Identification Color


Density 2%

Resistivity

2008 Fluxtrol, Inc.


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Primary
Material Characteristics

FLUXTROL A
Ideal for low and medium frequency applications (1-50kHz). Highest magnetic
permeability in the Fluxtrol family of soft magnetic materials. Material has
excellent mechanical strength, thermal conductivity and good machinability.
Proper material orientation must me taken into account for heavy loaded
Fluxtrol A
applications. (See Machining Section)

Density 2%

Green
g/cm3

6.6

Operating Frequency Range

kHz

150

Major Frequency Range

kHz

330

Initial Permeability

63

Maximum Permeability

120

Saturation Flux Density

Tesla

1.6

Temperature Resistance

Centigrade

250 Long Term


300 Short Term

Resistivity

kOhmcm

0.5

Thermal Conductivity

W/cm C

0.2

Fluxtrol A Magnetic Flux Density vs. Magnetic Field Strength


Magnetic Flux Density, Gs

Product Identification Color

Fluxtrol
A

12000
10000
8000
6000
4000
2000
0
0

10

20

30

40

50

60

70

80

90 100

Magnetic Field Strength, A/cm

Fluxtrol A Permeability vs. Magnetic Field Strength


160

Permeability

Units

120
80
40
0
0

10

20

30

40

50

60

70

80

90

100

Magnetic Field Strength, A/cm

Fluxtrol A Permeability vs. Magnetic Flux Density


160

Permeability

Properties

120
80
40
0

3000

6000

9000

12000

Magnetic Flux Density, Gs

2008 Fluxtrol, Inc.


www.fluxtrol.com

Primary
Material Characteristics

FLUXTROL 50
Excellent performance over a wide range of frequencies (10-1000kHz). Ideal
magnetic permeability for low and medium frequency applications, yet offers
the highest permeability in the Fluxtrol family of soft magnetic materials in high
frequency applications. Material has excellent mechanical strength, machinability
and good thermal conductivity.
Fluxtrol 50

Density 2%

Yellow
g/cm3

6.1

Operating Frequency Range

kHz

10-1000

Major Frequency Range

kHz

50-500

Initial Permeability

36

Maximum Permeability

55

Saturation Flux Density

Tesla

1.5

Temperature Resistance

Centigrade

250 Long Term


300 Short Term

Resistivity

kOhmcm

0.5

Thermal Conductivity

W/cm C

0.06

Fluxtrol 50 Magnetic Flux Density vs. Magnetic Field Strength


Magnetic Flux Density, Gs

Product Identification Color

Fluxtrol
50

10000
7500
5000
2500
0
0

40

80

120

160

200

240

Magnetic Field Strength, A/cm

Fluxtrol 50 Permeability vs. Magnetic Field Strength


60

Permeability

Units

40
20
0
0

40

80

120

160

200

240

Magnetic Field Strength, A/cm

Fluxtrol 50 Permeability vs. Magnetic Flux Density


60

Permeability

Properties

40
20
0
0

2000

4000

6000

8000

10000

Magnetic Flux Density, Gs

2008 Fluxtrol, Inc.


www.fluxtrol.com

Primary
Material Characteristics

FERROTRON 559 H
Proven concentrator material with high electrical resistivity and strength.
Almost constant magnetic permeability over a range of magnetic flux densities
and frequencies (10-3000 kHz). Material has excellent mechanical strength
and machinability.
Ferrotron 559 H

Density 2%

Grey
g/cm3

5.9

Operating Frequency Range

kHz

10-3000

Major Frequency Range

kHz

50-1000

Initial Permeability

16

Maximum Permeability

18

Saturation Flux Density

Tesla

Temperature Resistance

Centigrade

250 Long Term


300 Short Term

Resistivity

kOhmcm

>15

Thermal Conductivity

W/cm C

0.04

Ferrotron 559H Magnetic Flux Density vs. Magnetic Field Strength


Magnetic Flux Density, Gs

Product Identification Color

Ferrotron
559 H

6000
5000
4000
3000
2000
1000
0
0

50

100

150

200

250

Magnetic Field Strength, A/cm

Ferrotron 559H Permeability vs. Magnetic Field Strength


20

Permeability

Units

16
12
8
4
0
0

40

80

120

160

200

Magnetic Field Strength, A/cm

Ferrotron 559H Permeability vs. Magnetic Flux Density


20

Permeability

Properties

16
12
8
4
0
0

1000

2000

3000

4000

5000

Magnetic Flux Density, Gs

2008 Fluxtrol, Inc.


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Specialty
Material Characteristics

FLUXTROL 25
Ideal magnetic permeability for medium to high frequency applications
(103000 kHz). Material has excellent mechanical strength, machinability and
good thermal conductivity.
Fluxtrol 25

Density 2%

Red
g/cm3

5.5

Operating Frequency Range

kHz

10-3000

Major Frequency Range

kHz

50-500

Initial Permeability

23

Maximum Permeability

28

Saturation Flux Density

Tesla

1.3

Temperature Resistance

Centigrade

250 Long Term


300 Short Term

Resistivity

kOhmcm

>100

Thermal Conductivity

W/cm C

0.04

Fluxtrol 25 Magnetic Flux Density vs. Magnetic Field Strength


Magnetic Flux Density, Gs

Product Identification Color

Fluxtrol
25

6000
4000
2000
0
0

50

100

150

200

Magnetic Field Strength, A/cm

Fluxtrol 25 Permeability vs. Magnetic Field Strength


30

Permeability

Units

20
10
0
0

40

80

120

160

200

Magnetic Field Strength, A/cm

Fluxtrol 25 Permeability vs. Magnetic Flux Density


30

Permeability

Properties

20
10
0
0

2000

4000

6000

Magnetic Flux Density, Gs

2008 Fluxtrol, Inc.


www.fluxtrol.com

Specialty
Material Characteristics

FERROTRON 119
Material has highest electrical strength and is ideal for high, to very high
frequency applications (10 5000 kHz). Almost constant permeability over a
wide range of flux densities and operating frequencies. Excellent machinability
and temperature resistance. May be used in combination with other high
frequency materials for smooth heat pattern control.
Ferrotron 119

Density 2%
Operating Frequency Range
Major Frequency Range

Black
g/cm3

4.8

kHz

105000

kHz

100-1000

Initial Permeability

Maximum Permeability

Saturation Flux Density

Tesla

0.8

Temperature Resistance

Centigrade

250 Long Term


300 Short Term

Resistivity

kOhmcm

>100

Thermal Conductivity

W/cm C

0.02

Ferrotron 119 Magnetic Flux Density vs. Magnetic Field Strength


Magnetic Flux Density, Gs

Product Identification Color

Ferrotron
119

2000
1500
1000
500
0
0

40

80

120

160

200

Magnetic Field Strength, A/cm

Ferrotron 119 Permeability vs. Magnetic Field Strength


10

Permeability

Units

8
6
4
2
0
0

40

80

120

160

200

Magnetic Field Strength, A/cm

Ferrotron 119 Permeability vs. Magnetic Flux Density


10

Permeability

Properties

8
6
4
2
0

400

800

1200

1600

2000

Magnetic Flux Density, Gs

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol

Material Selection
Guidelines

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

Notes for
Material Selection Guidelines

The information provided below is a general reference only to cover the majority
of applications. In certain cases (heavily loaded applications, coils with small
turn to turn gaps, special cooling conditions, etc.) these guidelines may be
non-optimal. For severe or special applications, please contact your Fluxtrol
representative or Fluxtrol directly and we will be happy to assist.
More information regarding material selection and application can be found
in Chapter 6 of the Induction Basic Training Course contained in Section 9 of
this manual.
All material may be used at frequency lower than rated. For example Fluxtrol 50
and Ferrotron 559H have been implemented successfully on low frequency,
below 10 kHz, coils.
Concentrator Selection Guide
Heavy Load Low Frequency

120

55
FLUXTROL 50

Low Load High Frequency

Permeability

FLUXTROL A

20
FERROTRON 559H

10

50

1000

3000

Frequency kHz

2008 Fluxtrol, Inc.


www.fluxtrol.com

General
Material Selection Guidelines

Coil Style

Frequency

Recommended Material

< 10 kHz
10-50 kHz
> 50 kHz

Fluxtrol A
Fluxtrol A or Fluxtrol 50
Fluxtrol 50

All Frequencies

Fluxtrol 50

< 50 kHz
> 50 kHz

Fluxtrol 50
Ferrotron 559H

< 50 kHz
> 50 kHz

Fluxtrol 50
Ferrotron 559H

Single Shot



Fastener / Channel

Hair Pin

Pancake

2008 Fluxtrol, Inc.


www.fluxtrol.com

General
Material Selection Guidelines

Coil Style

Frequency

Recommended Material

< 10 kHz
10-50 kHz
> 50 kHz

Fluxtrol A
Fluxtrol 50
Ferrotron 559H

< 50 kHz
> 50 kHz

Fluxtrol 50
Ferrotron 559H

< 10 kHz
10-50 kHz
>50 kHz

Fluxtrol A
Fluxtrol A or Fluxtrol 50
Fluxtrol 50

< 10 kHz
10-50 kHz
50-100 kHz
>100 kHz

Fluxtrol A
Fluxtrol A or Fluxtrol 50
Fluxtrol 50
Ferrotron 559H

< 10 kHz
10-50 kHz
50-100 kHz
>100 kHz

Fluxtrol A
Fluxtrol A or Fluxtrol 50
Fluxtrol 50
Ferrotron 559H

I.D. Single Turn





I.D. Multi Turn

O.D. Cylindrical



Split & Return




Transverse Flux



2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol

Machining

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

Notes for

Machining

Safety and Machining


FLUXTROL & FERROTRON flux concentrators are soft magnetic composites
consisting of metal powders and dielectric binders compacted at high
pressures with subsequent treatment.
Fluxtrol when in solid form, do not represent a fire hazard. However, the metal
powder or chips produced by machining may be a source of combustion.
The primary source of combustion is friction. Red hot chips or sparks may be
thrown off, fall or drop into the collection tray of a lathe, inside a band saw or
near the grinding wheel dust. If these sparks land on accumulated machining
dust or debris, they could cause a smoldering fire. If left unattended, a fire
could result.
WARNING: Do not vacuum while machining for dust collection.
Coolant is not suggested, in that it impedes the cutting process and is
not necessary.
Fluxtrol flux concentrator materials can be easily machined using common machine
tools and practices (i.e., turning, milling, drilling, grinding). Use sharp tools with
slow feed and high speed.
Please note that machining by the WaterJet, EDM and Laser methods are not
recommended and Fluxtrol cannot guarantee material performance or condition if
machined using these methods.
With respect to drilling Fluxtrol materials: the flux concentrator material may be
drilled for additional cooling, quenchant supply or mechanical attachments.
When drilling pay close attention to chip removal from the drill and the hole as
it is being drilled; clogged bits and or holes can result in material breakage or
incorrect dimensions. Make pilot holes for large diameter holes / bores, drill on
a 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 inserts
are recommended for heavy mechanical applications.
Fluxtrol A may chip on sharp edges due to strong anisotropy and the machined
surface may look different on different surface due to grain orientation.
Fluxtrol 50 and Ferrotron 559H may be machined into parts having sharp angles
and thin (less than 1mm) areas.
2008 Fluxtrol, Inc.
www.fluxtrol.com

Notes for

Machining

Safety and Machining (Continued)


Anisotropy of FLUXTROL & FERROTRON materials:
When material has different properties in different directions they say that
material is Anisotropic
Fluxtrol A has significant anisotropy due to its structure. In plane
perpendicular to pressing direction permeability and thermal conductivity are
significantly higher. Also, losses are lower in plane perpendicular to pressing
direction
Fluxtrol 50 has lower anisotropy than A, especially in
mechanical properties
Ferrotron 559H has much lower anisotropy due to higher content of binder
and different structure
Material orientation is essential for heavily loaded applications such as scanning
or single-shot hardening when concentrator losses are removed continuously
by heat transfer to the copper. For these cases orientation Best is strongly
recommended with orientation N1 as a second choice. It is because the highest
value of thermal conductivity is more important than slightly higher magnetic
losses in the poles.
For short heating cycles such as contour gear hardening, orientation N2 is the
second choice after Best because of lower losses in the poles than in the case
N1 and lower influence of thermal conductivity on concentrator temperature.
Orientation

Pressing
Pressing
direction
direction

Pressing
direction

N1

N1

N1

Parameter

N1

N2

Best

Losses

Max

Min

Min

Heat transfer
(thermal conduct.)

Max

Min

Max

N2

N2

N2

Optimal Machining

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

Material Etching

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

Notes for
Material Etching

Main Goal
To remove or modify conductive surface layer for better electrical resistance and
electrical 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 or
machining due to smearing of the surface metal particles. Different materials
behave differently in these operations.
Ferrotron 559 H and Ferrotron 119 do not form a conductive layer in pressing
or any machining operations (turning, milling, saw cutting, grinding). Etching is
recommended for electrical strength improvement and rust prevention. Electrical
strength may be important when significant external voltage applied to a thin
layer of concentrator.
Fluxtrol 25 and Fluxtrol 50 typically do not form conductive layers in machining
operations. However conductive layer may be formed on the side surfaces in
the process of pressing or some machining operations with dull tool, low speed
and high feed. Etching is recommended for surface improvement and for higher
electrical strength when the concentrator touches coil turns with different electric
potential (non-insulated multi-turn ID coils, long hair-pin and similar coils).
Fluxtrol A forms a conductive layer in the process of pressing and machining,
especially when the machining occurs in direction of pressing (see Chapter 6
Fluxtrol Materials on Induction Coils in the Training Course Basics of Induction
Heating and Magnetic Flux Control). Etching is recommended for surface
improvement in applications where the concentrator isnt subject to external
voltage application (single-turn cylindrical coils and similar as well as coils with
electrically insulated copper). Etching is strongly recommended for concentrators,
which experience application of external voltage (multi-turn coils without
electrical insulation of copper etc.).

2008 Fluxtrol, Inc.


www.fluxtrol.com

Notes for
Material Etching

Additional Possible Benefits (Continued)


Presence of conductive layer may be identified by measuring of touch resistance
using low-voltage ohmmeter (multimeter). If touch resistance on any surface is
less 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 material
particles and form conductive channels in concentrator, permanently damaging
the material.
Etching Materials
Dont use chloric or nitric acid; they do not provide good etched surface
and 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 organic
solvent 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 of
standard 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 be
effectively used for small batches of material
Use spacers between material pieces and between pieces and bath bottom
for secure contact of all the surface to solution

2008 Fluxtrol, Inc.


www.fluxtrol.com

Notes for
Material Etching

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 better
results (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 using
Ph meter such as PH 220 EXTECH Instruments
Ph factor of fresh solution must be in a range 2.8-3.5. When Ph factor goes
above 3.5, which corresponds to less acidic reaction, add more etching
agent to return Ph to required level
In the process of etching the solution color changes from light yellow to
dark 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 solutions
accepted at your plant; contact manufacturer for specific instructions.

NOTE: Contact Fluxtrol Inc. at +1.248.393.2000 or fluxtrol@fluxtrol.com for


additional information, questions or suggestions.

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol

Material Application &


Maintenance

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

Notes for
Material Application & Maintenance

Surface Preparation
Best FLUXTROL & FERROTRON material performance may be realized when
sufficient care is administered to prepare Flux Concentrator and Induction
Heating Coil in the area of attachment/interface as described below:
Flux Concentrator - Clean all surfaces that are to be in intimate contact with
Induction Heating Coil by removing any paint. Lightly sand with medium to
medium-fine emery paper (80-180 grit) to give adhesive a good gripping
surface. 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 wiping
it with an organic solvent (such as acetone). Lightly sand with medium to
medium-fine emery paper (80-180 grit) to give epoxy adhesive a good
gripping surface. Remove any accumulated dust by wiping with a clean
dry cloth.

Surface Preparation

Thoroughly Clean ALL Surfaces Indicated in Black

Induction Heating
Coil Tubing

Flux Concentrator

2008 Fluxtrol, Inc.


www.fluxtrol.com

Notes for
Material Application & Maintenance

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 in
the best possible thermal contact with the induction coil. This can be achieved
through the use of a uniform and thin layer of a thermally conductive medium
in-between the contact surfaces.
Adhesive Bonding
Adhesive Bonding is the most common method of attaching Fluxtrol flux
concentrator product to an induction heating coil. Any epoxy adhesive used
must have the following characteristics:
high temperature stability
low moisture absorption
high bond strength

chemical resistance
good thermal conductivity
electrically non-conductive

Care should be taken to clean all dirt, oils, greases and mechanically roughen
the contact surfaces prior to bonding. A thin layer of epoxy adhesive should be
applied to both the Fluxtrol product and induction coil copper contact surfaces
and then these two surfaces are to be brought into contact and held together
with light pressure. Wipe away the excess glue with a damp cloth and then
follow the curing instructions for the respective adhesive.

Adhesive Bonding
Thin Sheet between Concentrators

Black surfaces indicate


gap between flux
concentrator and coil filled with
thermally conductive adhesive

Flux Concentrator

Induction Heating Coil Tubing

2008 Fluxtrol, Inc.


www.fluxtrol.com

Notes for
Material Application & Maintenance

Adhesive Bonding (Continued)


For common applications, we suggest a gap or space in-between inductor
copper and Fluxtrol product of ~0.008 .012 (0.2 0.3 mm) and
the 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 Heat
Transfer Epoxy Resin (from www.epoxies.com) with a suggested gap in-between
inductor 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 for
use only in lightly loaded or short duty cycle inductor coils.

2008 Fluxtrol, Inc.


www.fluxtrol.com

Notes for
Material Application & Maintenance

Mechanical Fastening
Mechanical Fastening is another example of how Fluxtrol flux concentrators are
attached to an induction heating coil. The purpose of the mechanical fastener
is to keep the flux concentrator in place. A technique may be used where a
stud (i.e., screw or bolt made from brass or copper) is brazed to the induction
coil coupled with a clearance hole drilled through the Fluxtrol product. Use
where possible a thermal medium that is electrically non-conductive and
thermally conductive i.e., heat sink paste (usually silicone based), like those
used for mounting transistors in power supplies. Both the Fluxtrol product and
Inductor contact surfaces should be coated with a thin and uniform layer prior
to fastening. After tightening down the nut on the stud, excess paste should be
wiped away with a dry rag. Be careful not to over tighten the nut, as this may
lead to cracking of the Fluxtrol flux concentrator. Use of plastic nuts may work
to lessen the chance of cracking the concentrator.
Fluxtrol recommends using the appropriate removable thread locker such as
Loctite 246 high temp/medium strength thread locker for metal fasteners and
Loctite 425 for plastic fasteners. This will work to eliminate the possibility of the
mechanical fasteners loosening over time due to vibration and insure the Fluxtrol
material stays properly in place on the coil.
Mechanical Fastening

Thin Sheet between Concentrators

Black surfaces indicate


gap between flux
concentrator and coil filled with
thermally conductive adhesive

Stud Brazed to Coil

Flux Concentrator

Induction Heating Coil Tubing

2008 Fluxtrol, Inc.


www.fluxtrol.com

Notes for
Material Application & Maintenance

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 and
proper 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 concentrator
with a knife or other sharp object. If material surface exposed has a grey metallic
color and is solid, concentrator is still OK for operation.
A surface that is both dark and crumbling results from the material being
overheated and in this case the concentrator must be replaced. If coil lifetime
was 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 ground
protection the equipment will turn off quickly however there may be small areas
of the concentrator damaged by this sparking. Remove the damaged volume of
material with a sharp tool and eliminate the factor that caused the sparking to
occur (too small a gap, metal particles, etc.). The concentrator can continue to
work as long as the damaged area is small.

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

Standard Sizes

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

Standard Sizes

Listing of Standard Sizes


A wide range of standard sizes are listed below. In addition to this broad
range of standard sizes, we also have flexible manufacturing capabilities
corresponding to your requirements for special orders (i.e., custom flux
concentrator product formulas).
ROUNDS / BILLETS
SIZE in INCHES

SIZE in METRIC mm

0.37
0.50
0.75
1.00
1.25
1.25
1.50
1.50
1.75
1.75
2.00
2.00
2.30
2.30
2.30
2.50
2.50
2.76
2.76
2.76
3.00
3.00
3.00
3.50
3.50
3.50
4.00
4.00
4.50
4.50
5.00
5.00
5.00
6.00
6.00
6.00
6.50
6.50
6.50

(9.4 x 50.8)
(12.7 x 50.8)
(19.0 x 50.8)
(25.4 x 50.8)
(31.7 x 76.2)
(31.7 x 76.2)
(38.1 x 50.8)
(38.1 x 76.2)
(44.5 x 50.8)
(44.5 x 76.2)
(50.8 x 50.8)
(50.8 x 76.2)
(58.4 x 50.8)
(58.4 x 76.2)
(58.4 x 130)
(63.5 x 50.8)
(63.5 x 63.5)
(70.1 x 50.8)
(70.1 x 63.5)
(70.1 x 76.2)
(76.2 x 25.4)
(76.2 x 50.8)
(76.2 x 76.2)
(89.0 x 25.4)
(89.0 x 50.8)
(89.0 x 63.5)
(101.5 x 25.4)
(101.5 x 50.8)
(114.3 x 25.4)
(114.3 x 50.8)
(127.0 x 6.3)
(127.0 x 25.4)
(127.0 x 50.8)
(152.4 x 6.3)
(152.4 x 25.4)
(152.4 x 50.8)
(165.1 x 6.3)
(165.1 x 25.4)
(165.1 x 50.8)

Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia

x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

2.00
2.00
2.00
2.00
2.00
3.00
2.00
3.00
2.00
3.00
2.00
3.00
2.00
3.00
5.12
2.00
2.50
2.00
2.50
3.00
1.00
2.00
3.00
1.00
2.00
2.50
1.00
2.00
1.00
2.00
0.25
1.00
2.00
0.25
1.00
2.00
0.25
1.00
2.00

2008 Fluxtrol, Inc.


www.fluxtrol.com

Standard Sizes

Listing of Standard Sizes (Continued)


SMALL RECTANGULAR BLOCKS


SIZE in INCHES
0.25
0.25

0.50
0.50
0.50
0.50
0.50
0.63
0.63
0.63
0.63
0.75
0.75
0.75
0.75

1.00
1.00
1.00
1.00
1.00
1.00
1.00

SIZE in METRIC mm

x 1.00 x 4.00
x 1.50 x 4.00

(6.3 x 25.4 x 101.5)


(6.3 x 38.1 x 101.5)

x
x
x
x
x
x
x
x
x
x
x
x
x

0.50
0.75
1.00
1.50
2.00
0.63
0.75
1.00
2.00
0.75
1.00
1.50
2.00

x
x
x
x
x
x
x
x
x
x
x
x
x

4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00

(12.7 x 12.7 x 101.5)


(12.7 x 19 x 101.5)
(12.7 x 25.4 x 101.5)
(12.7 x 38.1 x 101.5)
(12.7 x 50.8 x 101.5)
(16 x 16 x 101.5)
(16 x 19 x 101.5)
(16 x 25.4 x 101.5)
(16 x 50.8 x 101.5)
(19 x 19 x 101.5)
(19 x 25.4 x 101.5)
(19 x 38.1 x 101.5)
(19 x 50.8 x 101.5)

x
x
x
x
x
x
x

1.00
1.00
1.00
1.25
1.50
1.50
2.00

x
x
x
x
x
x
x

2.00
3.00
4.00
4.00
3.00
4.00
4.00

(25.4
(25.4
(25.4
(25.4
(25.4
(25.4
(25.4

x
x
x
x
x
x
x

25.4
25.4
25.4
31.7
38.1
38.1
50.8

x
x
x
x
x
x
x

50.8)
76.2)
101.5)
101.5)
76.2)
101.5)
101.5)

2008 Fluxtrol, Inc.


www.fluxtrol.com

Standard Sizes

Listing of Standard Sizes (Continued)


LARGE RECTANGULAR BLOCKS


SIZE in INCHES
0.25
0.50
0.63
0.75
1.00

0.38
0.50
0.75
1.00

0.38
0.50
0.75
1.00

0.38
0.50
0.75
1.00

SIZE in METRIC mm

x
x
x
x
x

4.00
4.00
4.00
4.00
4.00

x
x
x
x
x

7.75
7.75
7.75
7.75
7.75

(6.3 x 101.5 x 197)


(12.7 x 101.5 x 197)
(16.0 x 101.5 x 197)
(19.0 x 101.5 x 197)
(25.4 x 101.5 x 197)

x
x
x
x

6.12
6.12
6.12
6.12

x
x
x
x

8.12
8.12
8.12
8.12

(9.6 x 156 x 206)


(12.7 x 156 x 206)
(19.0 x 156 x 206)
(25.4 x 156 x 206)

x
x
x
x

3.00
3.00
3.00
3.00

x
x
x
x

8.12
8.12
8.12
8.12

(9.6 x 76 x 206)
(12.7 x 76 x 206)
(19.0 x 76 x 206)
(25.4 x 76 x 206)

x
x
x
x

4.00
4.00
4.00
4.00

x
x
x
x

6.12
6.12
6.12
6.12

(9.6 x 102 x 156)


(12.7 x 102 x 156)
(19.0 x 102 x 156)
(25.4 x 102 x 156)

For price and delivery information and also for custom sizes and/or machined
parts, please contact Fluxtrol at 248-393-2000 / 800-224-5522
sales@fluxtrol.com

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol LRM

Direct Lamination
Replacement

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

Fluxtrol
Direct Lamination Replacement

Using Fluxtrol greatly reduces the labor intensive task of stacking and attaching
laminations individually. All FLUXTROL & FERROTRON materials, being
solid in form, eliminate the degradation/corrosion build up that is common
between individual laminations. Lamination degradation can result in coil failure
or changes to the heat pattern. Another significant benefit of FLUXTROL &
FERROTRON materials is that they can be easily machined. This includes in-field
modification when necessary which is not possible with individual laminations.
Induction Coils Perform Better
Improved coil lifetime with
Fluxtrol LRM versus laminations
due to reduced copper thermal
racheting.
No overheating in the presence
of 3D magnetic fields.
Fluxtrol LRM covers more of the
inductor for greater efficiency.
Fluxtrol LRM can be positioned
without keepers for enhanced
heat pattern control.
Fluxtrol LRM Benefits
Cost effective alternative to
laminations with fast delivery.
Less construction time versus
laminations.
Available in near-net shapes
and finished to size.
Copper operates at lower
temperatures with Fluxtrol LRM
versus laminations.
FLUXTROL The Ultimate Lamination Replacement Material for Your Next Coil!

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol
Direct Lamination Replacement

Fluxtrol Lamination Replacement Material (LRM)


Fluxtrol LRM utilizes the anisotropic nature of the magnetic
composite material to maximize flux concentrator and
induction coil performance
Optimal orientation of material in C-shaped concentrator
provides high permeability, lower losses and:
Magnetic and thermal properties are higher
in the direction perpendicular to pressing.
Electrical strength is higher in direction of pressing

F Pressure Direction
B Flux Density
P Heat Transfer

Induction Coil Runs Cooler with Fluxtrol LRM


Steady state temperature distribution in
the in pipe seam anneal induction coil
with laminations
Temperature scale 20 250 C

Laminations

Steady state temperature distribution in


the in pipe seam anneal induction coil
with Fluxtrol LRM
Temperature scale 20 250 C

Fluxtrol LRM

Temperature Evolution Curves in Critical Areas for Intermittent Heating


Maximum copper
temperature with
Fluxtrol LRM is 20 C less
than with Laminations,
temperature variation span
is 35 C lower

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol
Direct Lamination Replacement

Typical Failure Mode of Laminations

Crankshaft Coil Failure

Copper Coil Crack

Image illustrates lamination overheating in


a three dimensional field (blue edges)

Copper failure due to thermal racheting


on crankshaft coil with lamination

Comparison of Lifetime Improvement with Fluxtrol LRM


Coil Lifetime with Fluxtrol LRM was
2.3 times longer than coil laminations
over an 18 month period.

Lamination

Fluxtrol LRM
Fluxtrol LRM

Comparison of Laminates versus Fluxtrol LRM


Fluxtrol LRM (right) has equivalent
heating to laminations (left)

Lamination

Fluxtrol LRM

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol
Direct Lamination Replacement

Fluxtrol Material Properties


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

Density 2%

g/cm3

6.6

kHz

.0530

Operating Frequency Range


Initial Permeability

63

Maximum Permeability

120

Saturation Flux Density

Tesla

1.6

Temperature Resistance

Centigrade

250 Long Term


300 Short Term

Resistivity

kOhmcm

0.5

Thermal Conductivity

W/cm C

0.2

Fluxtrol LRM Magnetic Flux Density vs. Magnetic Field Strength


Magnetic Flux Density, Gs

Fluxtrol
LRM

12000
10000
8000
6000
4000
2000
0
0

10

20

30

40

50

60

70

80

90 100

Magnetic Field Strength, A/cm

Fluxtrol LRM Permeability vs. Magnetic Field Strength


160

Permeability

Units

120
80
40
0
0

10

20

30

40

50

60

70

80

90

100

Magnetic Field Strength, A/cm

Fluxtrol LRM Permeability vs. Magnetic Flux Density


160

Permeability

Properties

120
80
40
0

3000

6000

9000

12000

Magnetic Flux Density, Gs

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol
Direct Lamination Replacement

Fluxtrol Material Properties (Continued)


FLUXTROL LRM Medium Frequency
Excellent performance over a wide range of frequencies (10-500kHz). Ideal
magnetic permeability for low and medium frequency applications, yet offers
the highest resistivity in the Fluxtrol LRM family of materials in medium frequency
applications. Material has excellent mechanical strength, machinability and
good thermal conductivity.

Density 2%

g/cm3

6.1

kHz

10-1000

Operating Frequency Range


Initial Permeability

36

Maximum Permeability

55

Saturation Flux Density

Tesla

1.5

Temperature Resistance

Centigrade

250 Long Term


300 Short Term

Resistivity

kOhmcm

10.0

Thermal Conductivity

W/cm C

0.1

Fluxtrol LRM MF Magnetic Flux Density vs. Magnetic Field Strength


10000

Magnetic Flux Density, Gs

Fluxtrol
LRM MF

7500
5000
2500
0
0

40

80

120

160

200

240

Magnetic Field Strength, A/cm

Fluxtrol LRM MF Permeability vs. Magnetic Field Strength


60

Permeability

Units

40
20
0
0

40

80

120

160

200

240

Magnetic Field Strength, A/cm

Fluxtrol LRM MF Permeability vs. Magnetic Flux Density


60

Permeability

Properties

40
20
0
0

2000

4000

6000

8000

10000

Magnetic Flux Density, Gs

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol
Direct Lamination Replacement

Standard Lamination Replacement Sizes


0.375
(9.52)

0.764
(19.4)

1.000
(25.4)

0.375
(9.52)

0.757
(19.2)

1.000
(25.4)

1.357
(34.5)

2.00
(50.8)
1.764
(44.8)

2.00
(50.8)

0.625
(15.9)

1.000
(25.4)

0.625
(15.9)

1.375
(34.9)

2.00
(50.8)

NOTE:
If your application requires
sizes/dimensions different than those
shown, please contact Fluxtrol
as custom sizes can be produced.
248-393-2000 / 800-224-5522
rjmadeira@fluxtrol.com

Fluxtrol LRM Application Methods

Fluxtrol LRM is Designed for:

Thermally conductive two part


epoxy is recommended.
In addition, the following mechanical
fasteners may be employed.
Secured by copper tabs
Brass studs with washers and nuts
Drawn together with flexible
bands
Trapped in place with nonconductive materials

Axle Bar coils


Crankshaft coils
Stem coils
Spindle & Bearing coils
Seam Anneal coils
Specialty Melting coils

Fluxtrol LRM is Aggressively Priced to Replace Laminations!


2008 Fluxtrol, Inc.
www.fluxtrol.com

Fluxtrol

Case Stories

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

Making the Case


Success 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 A chosen as concentrator
Condition simulated using computer simulation
Optimized coil design via computer simulation
New coil design utilizing Fluxtrol A built and tested
Tests meet spec and new coil put into production

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

2008 Fluxtrol, Inc.


www.fluxtrol.com

Making the Case


Success with Using Fluxtrol

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 times


Power supply at current limit
Customer need to increase production w/limited expense
Application evaluated and Fluxtrol 50 selected
No other changes were made other than
adding Fluxtrol 50
Tests meet spec and coil returned to production

Fluxtrol Advantage: Production Rate Increased 100%!

2008 Fluxtrol, Inc.


www.fluxtrol.com

Making the Case


Success with Using Fluxtrol

Application:

Automotive Camshaft / Static Hardening Coil

Original Concentrator:

None

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 A selected
No other changes were made other than
adding Fluxtrol A
Tests meet spec and coil returned to production

Fluxtrol Advantage: Cycle Time Reduced 26%, Power Reduced 30% and

No Back Tempering of Adjacent Lobes!

2008 Fluxtrol, Inc.


www.fluxtrol.com

Making the Case


Success with Using Fluxtrol

Application:

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

Original Concentrator:

None

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 time


Customer experiencing high scrap rates
Application evaluated and Fluxtrol A selected
No other changes were made other than adding
Fluxtrol A Fluxtrol applied per supplied guidelines
Tests meet spec and coil returned to production

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

2008 Fluxtrol, Inc.


www.fluxtrol.com

Making the Case


Success with Using Fluxtrol

Application:

Case Harden S-Cam and Shaft

Original Concentrator:

None

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 times


Customer experiencing loss of pattern control
Coil and application reviewed for pattern and time
Optimized coil design via computer simulation
New coil design utilizes Fluxtrol A material
Tests meet spec and coil returned to production

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

2008 Fluxtrol, Inc.


www.fluxtrol.com

Making the Case


Success with Using Fluxtrol

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 cycles


Laminations replaced with Fluxtrol A, no other changes
Lifetime increased to 15,000 to 20,000 cycles
Optimized coil design via computer simulation
New coil design utilizes Fluxtrol 50 material
Tests meet spec and coil returned to production

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

2008 Fluxtrol, Inc.


www.fluxtrol.com

Making the Case


Success with Using Fluxtrol

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 cycles


Fluxtrol given opportunity to replace laminations
Application evaluated and Fluxtrol 50 chosen
No 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!

2008 Fluxtrol, Inc.


www.fluxtrol.com

Fluxtrol

Induction Basic Training

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

Induction
Basic Training

Introduction
This Training Course is developed for people with different technical levels
(technology users, designers, coil manufacturers, businessmen etc.) for better
understanding of:
How induction heating works
Equipment used for induction heating applications
How to design optimal processes and induction coils using
computer 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 numerous
applications of induction heating. The main emphasis of this course is placed
on the theory, understanding and practice of magnetic flux control in induction
heating systems.

2008 Fluxtrol, Inc.


www.fluxtrol.com

Induction
Basic 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 work
on those older versions with only minor picture quality degradation
If you have difficulty in opening the files on the Basic Training CD please
contact Fluxtrol, Inc. (248-393-2000) so we can assist you by providing a
version that is compatible with your computer.

2008 Fluxtrol, Inc.


www.fluxtrol.com

ELTA

Simulation Software

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

ELTA
Software

ELTA Software
ELTA is a program for ELectroThermal Analysis of induction systems
Calculations in ELTA are based on a combination of 1D Finite Element
Method for closely coupled electromagnetic and thermal problems inside
the work piece and analytical method for account of finite lengths of the
part and induction coil. Special 2D numerical method is used for calculation
of 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 series
capacitors, matching transformer)
Possibility to simulate multi-stage processes such as part hardening and
tempering 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 created
by user templates

2008 Fluxtrol, Inc.


www.fluxtrol.com

ELTA
Software

When to Use ELTA


ELTA may be used for design of the whole system (heating time, frequency,
power, coil parameters, selection of power supplying circuitry) or as
an auxiliary tool for design of systems with complex geometry. Final
induction system optimization may be made using 2D (3D) program or
experimentally. ELTA is also an important tool for education, training and
business 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-or


multi-inductor lines

Heating of Slabs and strips in single- or


multi-inductor lines

2008 Fluxtrol, Inc.


www.fluxtrol.com

ELTA
Software

When to Use ELTA (Continued)

Local heating and surface hardening of


cylindrical or flat bodies

Scan hardening of flat surfaces

Scan hardening of cylindrical parts


2008 Fluxtrol, Inc.
www.fluxtrol.com

ELTA
Software

Using ELTA Software Screen Examples

Screen of workpiece geometry description

Screen of induction coil

Screen of Supplying Circuitry


2008 Fluxtrol, Inc.
www.fluxtrol.com

ELTA
Software

Design of In-Line Heat Treating Process


In-Line processes are becoming more popular in industry. In these processes
durations of all stages of in-line process (Austenization, Quenching, Tempering
and 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 slightly
under 4 sec. at optimal frequency 3kHz. This time was selected as a base
for other stages:
Austenization 4sec
Quenching 8 sec
Tempering 4 + 4 sec
Final cooling 8 sec

Induction System Geometry

2008 Fluxtrol, Inc.


www.fluxtrol.com

ELTA
Software

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.

Load/Unload
Austenitizing
Quenching
Tempering
Cooling

Rotary Table

Temperature evolution in optimized process:

Cycle Diagram

Color Map of Temperature Distribution

Green part surface


Red center
Black temperature differential

Color Map of temperature distribution shows that at the end of the first stage a
depth of austenitized layer (T> 800 C) is 4 mm as required.
After 8-second quenching, temperature at the depth of 4 mm dropped below
120 C, which is sufficient for complete martensite transformation, while
temperature at the center remained around 300 C.
This residual temperature and two-stage heating for tempering provided very
uniform temperature in hardened layer during tempering process.
2008 Fluxtrol, Inc.
www.fluxtrol.com

ELTA
Software

Design of In-Line Heat Treating Process (Continued)

3D presentation of temperature evolution

Cooling curves at different distances from surface

2008 Fluxtrol, Inc.


www.fluxtrol.com

ELTA
Software

Report Automatically Generated by ELTA

2008 Fluxtrol, Inc.


www.fluxtrol.com

ELTA
Software

Demonstration Example of Scanning Process Designed with ELTA


Industrial robot moves hairpin inductor along the curved surface of water-cooled
stand made of stainless steel.
Fluxtrol concentrator is installed on one half of the coil. There is almost no heating
under the coil part without concentrator.

Example of hairpin Inductor with concentrator on one half of coil

Temperature distribution was accurately predicted by the ELTA program.

2008 Fluxtrol, Inc.


www.fluxtrol.com

1388 Atlantic Boulevard


Auburn Hills, MI 48326 USA

P: 1.248.393.2000
1.800.224.5522 USA
F: 1.248.393.0277

www.fluxtrol.com
sales@fluxtrol.com
2008 Fluxtrol, Inc.
www.fluxtrol.com

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