Fluxtrol Materials for Flux ControlFluxtrol Inc. produces 3 primary materials and 5 new

Primary products:• Fluxtrol A

• Fluxtrol 50

• Ferrotron 559 H

New products:• Alphaform LF, MF and HF• Fluxtrol 100 (similar to Fluxtrol A with improved

anisotropy and thermoconductivity)• Fluxtrol LF Low Frequency material

Fluxtrol Material Parameters         

Properties Units Ferrotron 559H Fluxtrol 50 Fluxtrol A         

Density ± 2%g/cm3 5.9 6.1  6.6 

Initial   16 36 63Permeability  

Maximum   18 55 120Permeability        Saturation Tesla 1 1.5 1.6

Flux      Density        

Operating kHz 10- 10- 1-Frequency Range 3000 1000 50Temp. Resistance      

Long Term Centigrade 250 250 250Short Term   300 300 300

Thermal W/cm C 0.04 0.06 0.2Conductivity        

Resistivity kOhmcm >15 0.5 0.5         

New Fluxtrol Material Parameters     

Fluxtrol LF Alphaform LF  AlphaformMF  Alphaform HFProperties Units Fluxtrol 100    

Densityg/cm3

 6.9

 6.7

 4.1

 4.0

 3.9± 2%

Initial   80 

80 

11 

9.8 

8.8 Permeability  

Maximum   130 

165 

13 

10 

9 Permeability  

Saturation Tesla 1.8  

1.8  

1.0  

1.0  

1.0  

FluxDensity  

Operating kHz 0.05 0.05 1- 10- 20-Frequency

Range 50 3 80 450 3000

Temp. Resistance          

Long Term Centigrade 200 200 225 225 225 

Thermal W/cm C 0.23 0.22 0.02 0.02 0.02Conductivity            

Resistivity kOhmcm 12.5 0.004 >15 >15 >15             

Alphaform Materials

• Developed by Alpha 1 on the

basis of magnetic particles with

a thermal-curing epoxy binder

• Can be used for quick &

efficient results

• Material is formable when

warm

• Three versions are in

production at present time for

high (HF), middle (MF) and

low (LF) frequencies

Alphaform Application for ID Coils

Material easily fills internal volumes providing good heat

transfer to water-cooled turns.

Same inductor, one bare, the other with Alphaformshown induction heating steel pipe @ identical

power settings for 6.0 seconds.

BARE ALPHAFORM

Alphaform Application

• Main applications: - Small ID and complex geometry coils - Coils with odd turn surfaces (e.g. round tubes)- “In-house” made coils- Concentrator repair• Permeability:

Alphaform LF - 12

Alphaform MF - 10

Alphaform HF - 8• High electrical resistance• Electrical strength is 250 Vm/mm

Fluxtrol 100• Fluxtrol 100 created to substitute

Fluxtrol A• Advantages: Fluxtrol 100 has

lower anisotropy and higher thermal conductivity

• Performance of Fluxtrol 100 less dependable on cutting direction

0 50 100 150 200 250 3000

20

40

60

80

100

120

140

Fl.100 reg.

Fl. 100 perp.

Fl. A reg.

Fl. A perp.

Per

mea

bili

ty

Permeability vs. Field Strength

Field Strength, A/cm

Thermoconductivity of Fluxtrol 100:0.212 in direction of pressing0.227 in direction perpendicularto pressingThermoconductivity of Fluxtrol A:0.032 in direction of pressing0.211 in direction perpendicularto pressing

Fluxtrol 100 Application• Fluxtrol 100 has better thermoconductivity & less anisotropy

making it more fabrication friendly

Fluxtrol LF Material

• Fluxtrol LF is a new material designed for low frequency applications (up to 2-3 kHz):

- Hardening of big parts (rolls etc.)

- Seam annealing

- Tube heating

- Shielding in melting furnaces etc.

- Transverse Flux strip heating, etc.• Large volume applications are

expected, which will allow us to keep lower price

Initial permeability 80

Max permeability 160

Low losses at LF

- Material has good machinability- Thermoconductivity: 0.22 W/cmK)- Long term temperature resistance

@ 200 C, which is sufficient for LF applications (shunts, shields etc.)

- Volumetric electrical resistivity is 4 Ohmcm, which is sufficient for low frequencies

- Low electrical strength may be compensated by design measures.

Fluxtrol LF Properties

Water-Cooled Magnetic Templates

• Fluxtrol LF as well as Fluxtrol 100 may be used in multiple high temperature heating applications due to good temperature resistance and thermal conductivity

• Computer simulation can be made to find maximum temperature in water-cooled templates exposed to radiation from a hot flat body

Examples of water-cooled templatesDimensions 32.7 x 88 x 222 mm (1.3 x 3.5 x 8.8”)

Fluxtrol Gluing and Attachment• Copper & Fluxtrol surfaces should be prepared by roughing (scratching) up mating surfaces with a 50-100 grit

sandpaper• Proper epoxy selection is critical, and Fluxtrol Inc. recommends for typical applications JB Weld Epoxy Resin Part

#8265-S & 8265• A layer of epoxy should be applied to both the Fluxtrol Concentrator and the Induction Heating Coil• Clamp on even surface to secure proper positioning during cure• Remove excess epoxy for easier clean up (hot water works well)• For heavily loaded applications w/ high flux density and long duty cycles we recommend 50-3100 Epoxy Resin

(epoxies.com)• Follow manufacturers instructions for cure times• Mechanical attachment may also be used by mounting a stud or threaded boss to Induction Coil. Epoxy is still

recommended for good thermal bond efficiency

USE OF STUDS TO SECURE FLUXTROL PLATES CLAMPING FLUXTROL IN PLACE

ELECTRICAL VARNISHES

Corrosion protection Electrical insulating varnishes, paints & coatings

Electrical insulation Ceramic & nylon coatings

Antiseptic (FDA Standards) PTFE sealants for wear & chemical resistance

Impregnation Improved machinability w/ non-porous surface

Material Coatings

CERAMIC COATING PTFE COATING RESIN IMPREGNATION

Fluxtrol Machinability

1” THICK FLUXTROL 100 LOGO CUT WITH WATERJET TECHNOLOGY

CNC PRODUCED FLUXTROL 100 DETAILS FLUXTROL DETAIL W/ 1 MM WALL THICKNESS

FLUXTROL LF DETAILS MADE W/ STRD MILL TOOLS

Summary

• Soft Magnetic Composites proved to be effective materials for magnetic flux control in different induction systems due to ability to work in 3D fields, excellent machinability, good thermal conductivity and magnetic permeability sufficient for majority applications

• Different Fluxtrol materials cover the whole range of frequencies used in induction technique from 50 Hz up to 13.56 MHz