Fluxtrol produces magnetic materials for flux control applications including Fluxtrol A, Fluxtrol 50, and Ferrotron 559H. It also produces new materials such as Fluxtrol 100, Fluxtrol LF, and Alphaform grades. The materials have different properties like density, permeability, thermal conductivity and resistivity suited for different frequency ranges from 50Hz to 13.56MHz. Fluxtrol 100 was created as an improved substitute for Fluxtrol A with lower anisotropy and higher thermal conductivity. Fluxtrol LF is designed for low frequency applications up to 3kHz such as heating of large parts.

1. Fluxtrol 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 (similar to Fluxtrol A with improved
anisotropy and thermoconductivity)
• Fluxtrol LF Low Frequency material

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

3. New Fluxtrol Material Parameters
Fluxtrol LF Alphaform LF AlphaformMF Alphaform HFProperties Units Fluxtrol 100
Density
g/cm3
6.9 6.7 4.1 4.0 3.92%
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
Flux
Density
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 0.02
Conductivity
Resistivity kOhmcm 12.5 0.004 >15 >15 >15

4. 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

5. 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 Alphaform
shown induction heating steel pipe @ identical
power settings for 6.0 seconds.
BARE ALPHAFORM

6. 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

7. 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
20
40
60
80
100
120
140
0 50 100 150 200 250 300
Fl.100 reg.
Fl. 100
perp.
Fl. A reg.
Fl. A perp.
Permeability
Permeability vs. Field
Field Strength, A/cm
Thermoconductivity of Fluxtrol 100:
0.212 in direction of pressing
0.227 in direction perpendicular
to pressing
Thermoconductivity of Fluxtrol A:
0.032 in direction of pressing
0.211 in direction perpendicular
to pressing

8. Fluxtrol 100 Application
• Fluxtrol 100 has better thermoconductivity & less
anisotropy making it more fabrication friendly

9. 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

10. 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

11. 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 templates
Dimensions 32.7 x 88 x 222 mm (1.3 x 3.5 x 8.8”)

12. 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

13. 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

14. 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

15. 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