Chapter 0: Fluxtrol Introduction to Induction Heating Technology and Magnetic Flux Control

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http://fluxtrol.com Fluxtrol Inc. is pleased to offer you the following series of the Basics of Induction Heating presented here by Dr. Valentin Vemkov (2006)

Technology Business

2006 TRAINING COURSE BASICS OF INDUCTION TECHNIQUE and MAGNETIC FLUX CONTROL ,[object Object],[object Object]

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[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],It is not possible to describe in a short course all the features and numerous applications of induction heating. The main emphasis will be placed on the theory, understanding and practice of magnetic flux control in induction heating systems. Introduction

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History of Induction Heating ,[object Object],[object Object],[object Object],[object Object],See Historical Overview

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Latest Achievements in Induction Heating Technique ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

http://fluxtrol.com It is well known that performance of some induction systems may be significantly improved by application of magnetic flux controllers. They are used to concentrate, shield and/or redistribute the magnetic field which generates power in the part. Theoretical and practical evidences are presented in the paper, which show that there is still significant potential for improvement in innovative and traditional induction technologies due to magnetic flux control. Utilizing magnetic flux controllers in heat treating processes results in excellent heat pattern control and improvement of parameters of inductors and entire power delivery systems. In melting systems, especially in the case of vacuum furnaces, cold crucible and other specialty furnaces, the magnetic control can provide energy savings, magnetic field shielding, shorter melting cycles and optimized field distribution for metallurgical processes. Comparison of different groups of materials for magnetic flux control (laminations, ferrites and Soft Magnetic Composites, aka Magnetodielectrics) is also presented in the paper. Several examples of magnetic flux control illustrate the presented material based on more than 20 years of R&D and practical experience of scientists and practitioners at Fluxtrol Inc.

* Basics of Induction heating and heat treating * Role and specifics of induction technology in heat treating in automotive parts * Main processes of induction heat treating of automotive parts * Computer simulation and optimization of induction processes and heating coils * Advanced design of induction coils * Magnetic controllers on induction coils * Induction coil manufacturing * Maintenance of induction coils * Stresses and distortions in the process of induction heating * Examples of induction heat treating (parts, processes, coils, installations) * Conclusions

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In recent years, there has been a significant increase in the customer demands for improved induction coil lifetime. This has led to several publications in recent years by induction tooling manufacturers [1-4]. The main conclusion in these papers is that besides mechanical crashes the cause of most induction coil failures is localized overheating of the coil copper due to insufficient cooling. What is lacking from these publications is any way to determine what is sufficient cooling. In this paper, a scientific method for determining local copper temperatures will be presented. This will include evaluations of heat transfer coefficients for different sections of a multi-component inductor, dependence of heat transfer coefficient on water pressure and water passage cross-section, non-uniform power density distributions in various 2-D cross-sections and the resulting temperature distribution in the copper winding. The effects of duty cycle on optimal design will also be considered.

Increasing Inductor Lifetime by Predicting Coil Copper Temperatures Presentation

Fluxtrol Inc.

Recognizing and Eliminating Flux Concentrator Failures

Fluxtrol Inc.

Specification and Use of a Flux Concentrator

Fluxtrol Inc.

ASM 2013 Fluxtrol Paper - Innovations in Soft Magnetic Composites and their A...

Fluxtrol Inc.

http://fluxtrol.com In induction hardening, thermal fatigue is one of the main failure modes of induction heating coils. There have been papers published that describe this failure mode and others that describe some good design practices [1-3]. The variables previously identified as the sources of thermal fatigue include radiation from the part surface, frequency, current, concentrator losses, water pressure and coil wall thickness. However, there is very little quantitative data on the factors that influence thermal fatigue in induction coils available in the public domain. By using finite element analysis software this study analyzes the effect of common design variables of inductor cooling, and quantifies the relative importance of these variables. A comprehensive case study for a single shot induction coil with Fluxtrol A concentrator applied is used for the analysis.

ASM 2013 Fluxtrol Presentation - Innovations in Soft Magnetic Composites and ...

Fluxtrol Inc.

ASM 2013 Fluxtrol Presentation - Enhancing Inductor Coil Reliability

Fluxtrol Inc.

Presentation on Effect of Spray Quenching Rate on Distortion and Residual Str...

Fluxtrol Inc.

http://fluxtrol.com Computer simulation is used to predict the residual stresses and distortion of a full-float truck axle that has been induction scan hardened. Flux2D® is used to model the electromagnetic behavior and the power distributions inside the axle in terms of time. The power distributions are imported and mapped into DANTE® model for thermal, phase transformation and stress analysis. The truck axle has three main geometrical regions: the flange/fillet, the shaft, and the spline. Both induction heating and spray quenching processes have significant effect on the quenching results: distortion and residual stress distributions. In this study, the effects of spray quenching severity on residual stresses and distortion are investigated using modeling. The spray quenching rate can be adjusted by spray nozzle design, ratio of polymer solution and quenchant flow rate. Different quenching rates are modeled by assigning different heat transfer coefficients as thermal boundary conditions during spray quenching.

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