Fluxtrol produces soft magnetic composites (SMCs) for magnetic flux control in induction systems. Their primary materials are Fluxtrol A, Fluxtrol 50, and Ferrotron 559H, while their new products include Alphaform LF/MF/HF, Fluxtrol 100, and Fluxtrol LF. SMCs can be machined, coated, impregnated, and used to control magnetic fields for applications like coil cores and magnetic templates. Alphaform is a formable SMC for complex geometries, and Fluxtrol 100 improves on Fluxtrol A with lower anisotropy. SMCs effectively control magnetic fields over wide frequency ranges and temperatures for induction applications.

1. Innovations in Soft Magnetic
Composites and their Applications
in Induction Systems
Dr. V. Nemkov, Dr. N. Vyshinskaya, R.T. Ruffini
R. Goldstein, C. Yakey

2. Overview
• SMC for magnetic flux control in induction
systems
• Properties of Fluxtrol materials
• Application technique for:
- Formable materials
- Solid materials
• Coating
• Impregnation
• Machining
Coil for axle hardening
with magnetic controller

3. Materials for Flux Control
Fluxtrol 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 (instead of Fluxtrol A)
• Fluxtrol LF (Low Frequency)
Remelting of plasma
coated layer on a shaft

4. Parameters of Primary Materials
Properties
Units
Density ± 2%
Initial
Permeability
Maximum
Permeability
Saturation
Flux Density
g/cm3
Ferrotron
559H
5.9
-
Frequency Range
Fluxtrol 50
Fluxtrol A
6.1
6.6
16
36
63
-
18
55
120
Tesla
1
1.5
1.6
kHz
10-3000
10-1000
1-50
250
300
250
300
250
300
0.04
0.06
0.2
>15
0.5
0.5
Temp. Resistance
Long Term
Celsius
Short Term
Thermal
W/cmK
Conductivity
Resistivity
kOhmcm

5. Parameters of New Materials
Properties
Density
± 2%
Initial
Permeability
Maximum
Permeability
Saturation
Flux Density
Frequency
Range
Units
g/cm3
--Tesla
kHz
Fluxtrol Fluxtrol
100
LF
Alphaform
MF
LF
HF
6.9
6.7
4.1
4.0
3.9
80
80
11
9.8
8.8
130
165
13
10
9
1.6
1.8
1.0
1.0
1.0
1 - 80
10 450
20 3000
0.05 - 50 0.05 - 3
Temperature
Resistance
Celsius
200
200
225
225
225
Thermal
Conductivity
W/cm K
0.23
0.22
0.02
0.02
0.02
Resistivity
kOhmcm
12.5
0.004
>15
>15
>15

6. Alphaform Materials
• Developed by Alpha One on the
basis of magnetic particles with
a thermal-curing epoxy binder
• Material is formable when warm
• Can be used for quick & efficient
installation to coils with low
tolerances
• Three versions are available:
for high (HF), middle (MF)
and low (LF) frequencies
Tin packages with formable
material

7. 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

8. Alphaform Application for ID
Coils
BARE
Material easily fills internal
volumes providing good heat
transfer to water-cooled turns
ALPHAFORM
Bare inductor
Inductor with Alphaform MF
Heating steel pipe; same power settings; t = 6.0 sec

9. Fluxtrol 100
Permeability vs. Field Strength
140
Fl.100 reg.
120
Fl. 100 perp.
100
Fl. A reg.
80
Permeability
Fluxtrol 100 created to
substitute Fluxtrol A
Advantages:
• Fluxtrol 100 has lower
anisotropy and its
performance is less
dependent on cutting
direction
• Higher thermal
conductivity
• Higher mechanical
strength
Fl. A perp.
60
40
20
0
0
50
100
150
200
Field Strength, A/cm
250
300

10. Fluxtrol 100 Application
Induction coils for rotational hardening of crankshafts.
Concentrators are segmented to tolerate better the copper
extension during thermal cycles

11. Water-Cooled Magnetic Templates
• With internal water cooling Fluxtrol controllers may be
used in hot environment
• Computer simulation and experiments confirmed that
water-cooled templates carrying high magnetic field can
work in close proximity to the hot body
Water-cooled
template
Dimensions 32.7 x 88 x 222 mm (1.3 x 3.5 x 8.75”)

12. Material Coatings
 Corrosion protection
Varnishes, paints & coatings
 Electrical insulation
Varnishes, ceramic & nylon coating
 Clean room requirements
Teflon coating
 Aseptic (FDA standards)
VARNISH COATING
Teflon coating
ELECTRICAL VARNISHES
CERAMIC COATING
PTFE COATING

13. Teflon Coating
Teflon coating thickness can vary from several microns to
20 microns depending on coating type and technology

14. Impregnation
• Impregnation consists in parts soaking in a
special epoxy resin under vacuum
• Then resin penetrates into the open pores
under applied pressure
• Resin polymerizes inside the pores
• Excess of resin is being removed from the
surface

15. Impregnation Results
• Better mechanical properties and
machinability
• Lower surface and volumetric
corrosion
• Excellent gluing of all the
surfaces
• Magnetic properties don’t
change
• Increase of electrical resistivity
• Depth of penetration depends
upon the material type; e.g. for
Fluxtrol 50 it is app. 0.4”
Two impregnated samples
glued with epoxy 50-3100
Light areas – impregnated
layer

16. Sample of Fluxtrol 100 with
Stainless Steel Inserts for Bolts M5
Inserts have been screwed into
the material
Close view of
steel insert

17. Fluxtrol Machining
• Materials may be easily machined
(drilled, milled, turned, ground,
etc.).
• It is not necessary to use cooling or
lubricating fluids.
• Use sharp carbide tools (carbide
tools recommended)
• Use high spindle speed and slow
feed rate (e.g., < 30”/min)
• Make pilot holes when drilling large
bores.
• Use proper measures to evacuate
dust and remove chips.
FLUXTROL 100 DETAILS MADE W/ STRD MILL TOOLS
DETAIL W/ 1 MM WALL THICKNESS

18. Example: CNC Groove Machining

19. Waterjet Cutting
1” THICK FLUXTROL 100 LOGO CUT WITH WATERJET TECHNOLOGY
Waterjet is very effective for cutting flat profiles

20. 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
• Additional treatment of stock material or finished parts
allow to use magnetic controllers in special and
challenging environment
• More information about materials and their application
may be found on site www.fluxtrol.com
1388 Atlantic Blvd., Auburn Hills, MI, 48326
Ph. +1 248 393 2000, Fax +1 248 393 0277