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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
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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
250Long Term300Short Term
Ferrotron
119
Black
4.8
105000
1001000
7
8
0.8
250Long Term300Short Term
6.6
150
330
63
120
1.6
250Long Term300Short Term
Physical Characteristics Chart
Primary Products Specialized Products
Green
Resistivity kOhmcm 0.5 0.5 >15 >100 >100
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PrimaryMaterial Characteristics
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
Magnetic Field Strength, A/cm
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
Saturation Flux Density Tesla 1.6
Operating Frequency Range kHz 150
Major Frequency Range kHz 330
Temperature Resistance Centigrade 250Long Term300Short Term
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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PrimaryMaterial Characteristics
Magnetic Flux Density, Gs
Fluxtrol 50 Permeability vs. Magnetic Flux Density
Permea
bility
0
0
20
40
60
2000 4000 1000080006000
Magnetic Field Strength, A/cm
Fluxtrol 50 Magnetic Flux Density vs. Magnetic Field Strength
MagneticFluxDensity,
Gs
Magnetic Field Strength, A/cm
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
Density 2% g/cm3 6.1
Initial Permeability 36
Maximum Permeability 55
Saturation Flux Density Tesla 1.5
Operating Frequency Range kHz 10-1000
Major Frequency Range kHz 50-500
Temperature Resistance Centigrade 250Long Term300Short Term
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.
Resistivity kOhmcm 0.5
0.06
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PrimaryMaterial Characteristics
Properties Units
Product Identification Color
Density 2% g/cm3
Temperature Resistance Centigrade
Ferrotron
559 H
Grey
5.9
Initial Permeability 16
Maximum Permeability 18
Saturation Flux Density Tesla 1
Operating Frequency Range kHz 10-3000
Major Frequency Range kHz 50-1000
250Long Term300Short Term
0.04Thermal Conductivity W/cm C
Resistivity kOhmcm >15
Magnetic Flux Density, Gs
Ferrotron559H Permeability vs. Magnetic Flux Density
Permea
bility
0
0
4
8
16
12
20
1000 2000 3000 4000 5000
Magnetic Field Strength, A/cm
Ferrotron 559H Magnetic Flux Density vs. Magnetic Field Strength
MagneticFluxDensity,
Gs
Magnetic Field Strength, A/cm
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
Magnetic Flux Density, Gs
Fluxtrol 25 Permeability vs. Magnetic Flux Density
Permea
bility
0
0
10
20
30
2000 4000 6000
Magnetic Field Strength, A/cm
Fluxtrol 25 Magnetic Flux Density vs. Magnetic Field Strength
MagneticFluxDensity,
Gs
Magnetic Field Strength, A/cm
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
Product Identification Color
Density 2% g/cm3
Temperature Resistance Centigrade
Fluxtrol
25
Red
5.5
Initial Permeability 23
Maximum Permeability 28
Saturation Flux Density Tesla 1.3
Operating Frequency Range kHz 10-3000
Major Frequency Range kHz 50-500
250Long Term300Short Term
0.04Thermal Conductivity W/cm C
Resistivity kOhmcm >100
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
Magnetic Flux Density, Gs
Ferrotron 119 Permeability vs. Magnetic Flux Density
Permea
bility
0
0
4
2
6
8
10
400 800 1200 1600 2000
Magnetic Field Strength, A/cm
Ferrotron 119 Magnetic Flux Density vs. Magnetic Field Strengt
MagneticFluxDensity,
Gs
0
0
500
1000
1500
2000
40 80 120 160 200
Magnetic Field Strength, A/cm
Ferrotron 119 Permeability vs. Magnetic Field Strength
Permea
bility
0
0
2
4
6
10
8
40 80 120 160 200
Properties Units
Product Identification Color
Density 2% g/cm3
Temperature Resistance Centigrade
Ferrotron
119
Black
4.8
Initial Permeability 7
Maximum Permeability 8
Saturation Flux Density Tesla 0.8
Operating Frequency Range kHz 105000
Major Frequency Range kHz 100-1000
250Long Term300Short Term
0.02Thermal Conductivity W/cm C
Resistivity kOhmcm >100
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
> 50 kHz Ferrotron 559H
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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
> 50 kHz Ferrotron 559H
I.D. Multi Turn < 50 kHz Fluxtrol 50
> 50 kHz Ferrotron 559H
O.D. Cylindrical
< 10 kHz Fluxtrol A
10-50 kHz Fluxtrol A or Fluxtrol 50
>50 kHz Fluxtrol 50
Split & Return
< 10 kHz Fluxtrol A
10-50 kHz Fluxtrol A or Fluxtrol 50
50-100 kHz Fluxtrol 50
>100 kHz Ferrotron 559H
Transverse Flux
< 10 kHz Fluxtrol A
10-50 kHz Fluxtrol A or Fluxtrol 50
50-100 kHz Fluxtrol 50
>100 kHz Ferrotron 559H
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Fluxtrol
Machining
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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
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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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Notes forMaterial Etching
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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Notes forMaterial 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 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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Notes forMaterial 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 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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Notes forMaterial Application & Maintenance
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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Notes forMaterial Application & Maintenance
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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Notes forMaterial 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 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
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Fluxtrol LRM
Direct LaminationReplacement
1388 Atlantic BoulevardAuburn Hills, MI 48326 USA
P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277
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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
Fluxtrol Direct Lamination Replacement
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
Fluxtrol Direct Lamination Replacement
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 Direct Lamination Replacement
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.
Magnetic Flux Density, Gs
Fluxtrol LRM Permeability vs. Magnetic Flux Density
P
ermea
bility
0
0
40
80
120
160
3000 6000 9000 12000
Magnetic Field Strength, A/cm
Fluxtrol LRM Magnetic Flux Density vs. Magnetic Field Strengt
MagneticFluxDensity,
Gs
0
0
2000
4000
6000
8000
10000
12000
10 20 30 40 50 60 70 80 90 100
Magnetic Field Strength, A/cm
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
Initial Permeability 63
Maximum Permeability 120
Saturation Flux Density Tesla 1.6
Operating Frequency Range kHz .0530
Temperature Resistance Centigrade 250 Long Term300 Short Term
0.2Thermal Conductivity W/cm C
Resistivity kOhmcm 0.5
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Fluxtrol Direct Lamination Replacement
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.
Magnetic Flux Density, Gs
Permea
bility
0
0
20
40
60
2000 4000 1000080006000
Magnetic Field Strength, A/cm
Fluxtrol LRM MF Magnetic Flux Density vs. Magnetic Field Streng
MagneticFluxDensity,
Gs
Magnetic Field Strength, A/cm
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
Density 2% g/cm3 6.1
Initial Permeability 36
Maximum Permeability 55
Saturation Flux Density Tesla 1.5
Operating Frequency Range kHz 10-1000
Temperature Resistance Centigrade 250Long Term300Short Term
0.1Thermal Conductivity W/cm C
Resistivity kOhmcm 10.0
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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
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!
Fluxtrol Direct Lamination Replacement
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Fluxtrol
Case Stories
1388 Atlantic BoulevardAuburn Hills, MI 48326 USA
P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277
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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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Making the CaseSuccess 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 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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Making the CaseSuccess 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 Aselected
No other changes were made other thanadding Fluxtrol A
Tests meet spec and coil returned to production
Fluxtrol Advantage: Cycle Time Reduced 26%, Power Reduced 30% andNo Back Tempering of Adjacent Lobes!
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Making the CaseSuccess 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 timeCustomer experiencing high scrap rates
Application evaluated and Fluxtrol AselectedNo other changes were made other than addingFluxtrol AFluxtrol applied per supplied guidelines
Tests meet spec and coil returned to production
Fluxtrol Advantage: Cycle Time Reduced 42%, Positive Control of Heat Pattern!
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Making the CaseSuccess 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 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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Making the CaseSuccess 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 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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Making the CaseSuccess 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 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
1388 Atlantic BoulevardAuburn Hills, MI 48326 USA
P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277
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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
1388 Atlantic BoulevardAuburn Hills, MI 48326 USA
P: 1.248.393.2000 1.800.224.5522 USAF: 1.248.393.0277
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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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