The document discusses Fluxtrol, a company that provides magnetic flux concentrators and induction heating services. It describes how Fluxtrol's soft magnetic concentrators can be machined using various tools like band saws, mills, lathes, and drills. It also discusses Fluxtrol's laboratory which can test induction heating applications, and AlphaForm, a hand moldable induction flux concentrator that Fluxtrol provides for improving heating efficiency.

1. Gallery of Fluxtrol Magnetic
Flux Concentrator Machining,
Induction Brazing, Process
Improvement, AlphaForm, and Computer
Simulation
Fluxtrol.com 1-248-393-2000

2. Sawing Fluxtrol Induction Magnetic Flux Concentrators
All of the Fluxtrol soft magnetic
concentrators or controllers can be
cut using a band saw.
A wide variety of band saw
characteristics and parameters can be
used to effectively cut the material.
Fluxtrol.com 1-248-393-2000

3. Milling of Fluxtrol Induction Magnetic Flux
Concentrators
All of the Fluxtrol soft
magnetic concentrators
or controllers can be cut
using a milling machine.
A wide variety of milling characteristics
and parameters can be used to
effectively remove material.
Fluxtrol.com 1-248-393-2000

4. Turning of Fluxtrol Induction Magnetic Flux Concentrators
A wide variety of turning
characteristics and parameters can
be used to effectively remove material
All of the Fluxtrol soft magnetic
concentrators or controllers can be
cut using a lathe or turning machine.
Fluxtrol.com 1-248-393-2000

5. Drilling of Fluxtrol Induction Magnetic Flux
Concentrators
All of the Fluxtrol soft magnetic concentrators or controllers
can have holes drilled in them
A wide variety of drilling
characteristics and parameters
can be used to effectively
remove material
Fluxtrol.com 1-248-393-2000

6. Induction Coil Channel Concentrators
Fluxtrol induction
channel concentrators
come in virtually any
shape or size.
Fluxtrol.com 1-248-393-2000

7. Fluxtrol Induction Magnetic Flux
Concentrator Material Can Be Threaded
Fluxtrol.com 1-248-393-2000

8. Increase Induction Hardening Scan Speed
Induction Quench Design is Critical
to Axle Scanning Speed
Fluxtrol.com 1-248-393-2000

9. Induction Brazing of Rotor at 50 kHz
Fluxtrol LRM
concentrators can
localize
secondary, unwant
ed heating.
Fluxtrol.com 1-248-393-2000

10. Magnetic Low Conductive Material
Fluxtrol can provide
addition material
properties and in any
material shape for your
specific application.
Fluxtrol.com 1-248-393-2000

11. Magneto - Dielectric Materials
Completely machinable
into virtually any shape
Fluxtrol.com 1-248-393-2000

12. Induction Laminations Versus Fluxtrol’s LRM
Fluxtrol.com 1-248-393-2000

13. Induction Process Testing in Fluxtrol’s Laboratory
Fluxtrol’s Laboratory can
replicate many actual
induction heating
applications
Fluxtrol.com 1-248-393-2000

14. One Piece Machined Induction Crankshaft Head
Designs Result in Longer Fatigue Cycle Life
Fluxtrol.com 1-248-393-2000

15. Concentrator Replaces Laminations on
Induction Crankshaft Coil
Fluxtrol.com 1-248-393-2000

16. Robust
Crankshaft
Coil Design
Fluxtrol.com 1-248-393-2000

17. Heavy Duty
Induction
Crankshaft
Bearing Coil
Fluxtrol.com 1-248-393-2000

18. Induction Hardened Radius Pattern on
Diesel Crankshaft
Fluxtrol.com 1-248-393-2000

19. AlphaForm Hand Moldable Induction Flux Concentrator
Add layers of AlphaForm to the
induction coil as needed.
Fluxtrol.com 1-248-393-2000

20. AlphaForm Hand Moldable Induction Flux Concentrator
Unused AlphaForm can be returned to the
container, so there is no waste.
Fluxtrol.com 1-248-393-2000

21. Induction Hairpin Coil AlphaForm Heating Comparison
Right, a 3/16” hairpin
induction coil without
AlphaForm after 20
seconds of heating
Right, a 3/16” hairpin
induction coil with
AlphaForm after 20
seconds of heating
Fluxtrol.com 1-248-393-2000

22. AlphaForm Hand Moldable Induction Flux
Concentrator for Tubing Coils Efficiency
Fluxtrol’s AlphaForm soft, moldable magnetic flux
concentrators can be used with any copper tubing for
quick improvements.
Fluxtrol.com 1-248-393-2000

23. AlphaForm for Induction Process Development
• Apply AlphaForm to the induction coil
• Test your specific heating application
• If it yields good results, cure it in an
oven to permanently attach the
AlphaForm to the induction coil.
It can be added to improve a coil
and easily removed after testing.
Fluxtrol.com 1-248-393-2000

24. AlphaForm Formable Concentrator on
Induction Pancake Style Coil
AlphaForm can conform to
almost any coil geometry
AlphaForm can reduce
heat time and energy by
20 - 50%, with better heat
pattern and control.
Fluxtrol.com 1-248-393-2000

25. AlphaForm Induction Concentrator
Induction heating
comparison of a bare
induction pancake coil
and the same coil and
power with the
application of
AlphaForm, after 18
seconds of heating.
Fluxtrol.com 1-248-393-2000

26. AlphaForm, Soft, Moldable Induction Magnetic
Flux Concentrator for Multi-turn I.D. Coils
Fluxtrol’s
AlphaForm High and
Low
Frequency, Soft, Mol
dable Magnetic Field
Concentrators Can
be Used with
Difficult Induction
Coil Geometries and
Can be Pressed Into
Tight Spaces.
Fluxtrol.com 1-248-393-2000

27. AlphaForm, Doesn’t Need an Insulating
Material Between the Induction Coil Turns
Fluxtrol’s AlphaForm
is a soft, moldable
magnetic field
concentrator that
doesn’t need an
insulating material
between the coil
turns in most
applications.
Fluxtrol.com 1-248-393-2000

28. AlphaForm is Perfect for Small Induction Tubing
A cut through a multi-turn 3/16”, I. D. induction tubing
coil reveals that Fluxtrol’s AlphaForm, bonds completely
with the coil without gaps or separation.
Fluxtrol.com 1-248-393-2000

29. AlphaForm Moldable Magnetic Flux Concentrator
To the left, a bare 3/16” multi-turn I.D. induction coil without AlphaForm
and to the right the same induction coil with AlphaForm
Both coils below with the same power & 6 seconds of induction heating
Fluxtrol.com 1-248-393-2000

30. Transverse Flux Induction Tubing Coil With AlphaForm
Hand Moldable Induction Flux Concentrator
An induction “earmuff” brazing
coil without and with AlphaForm
hand moldable flux concentrator
Fluxtrol.com 1-248-393-2000

31. Transverse Flux Induction Tubing Coil With AlphaForm
Hand Moldable Induction Flux Concentrator
An induction coil without & with AlphaForm hand moldable
concentrator after 18 seconds of heating with the same kW’s.
Fluxtrol.com 1-248-393-2000

32. Induction Power Density in Coil
1kHz, 7,500A, 20psi 0.048 (t/δ = 0.48) 0.062 (t/δ = 0.63) 0.125 (t/δ = 1.26)
3kHz, 7,500A, 20psi 0.048 (t/δ = 0.84) 0.062 (t/δ = 1.09) 0.125 (t/δ = 2.19)
Fluxtrol.com 1-248-393-2000

33. Induction Coil Corner and Center Temperature Difference
t/δ = 0.48 t/δ = 4.03
• The reference depth is
shown to influence the
thermal profile in the coil
• As shown here, when the
wall thickness to reference
depth ratio is small the
temperature is higher in
the center, but when the
ratio is large it is higher in
1 kHz the corners. 10 kHz
7500 A 7500 A
40 psi 40 psi
0.048 in 0.125 in
Fluxtrol.com 1-248-393-2000

34. Induction Coil Thermal Profile During Heating
10kHz, 7,500A
40psi, 0.062
10 s 25 s 40 s 55 s
70 s 85 s 100 s 115 s
Fluxtrol.com 1-248-393-2000

35. Induction Coil Cycling Results
10kHz 7500A 0.062 40psi
200 Center Temperature
Corner Temperature
Concentrator Corner
150 Concentrator Backside
Temperature
( C)
100
50
0
0 20 40 60 80 100 120 140 160
Time (s)
Fluxtrol.com 1-248-393-2000