http://fluxtrol.com
Magnetodielectric materials play an important role in improvement of induction systems for heat treatment, brazing, soldering, sealing and other technologies. This presentation is a continuation of the report made at HIS-01. Current report shows the results of development of new magnetodielectric materials for magnetic flux control and intensive study of their properties.
Design and Fabrication of Inductors for Induction Heat TreatingFluxtrol Inc.
Â
FOR INDUCTION MELTING AND MASS HEATING, the early induction heating coils
were manufactured from copper tubing wrapped in multiple turns around a mandrel. The first induction heat treating coils were developed for
crankshaft hardening in the 1930s (Fig. 1, 2) (Ref 1–4). Unlike the melting and mass heating
coils, the heat treating induction coils were machined. These inductors consisted of two
parts with a hinge on one side that would open and shut around the crankshaft journal. Quench holes were drilled on the inner diameter of the induction coil to deliver quench to the part afterheating. This pioneering development was the culmination of many years of hard work by a large team and clearly demonstrated the different requirements for induction heat treating as compared to melting and mass heating.
Copyright 2014, ASM International, www.asminternational.org. This article was published in ASM Handbook, Volume 4C: Induction Heating and Heat Treatment and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this article for a fee or for commercial purposes, or modification of the content of this article is prohibited.
Copyright 2014, ASM International, www.asminternational.org. This article was published in ASM Handbook, Volume 4C: Induction Heating and Heat Treatment and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this article for a fee or for commercial purposes, or modification of the content of this article is prohibited.
SIMULATION OF INDUCTION SYSTEM FOR BRAZING OF SQUIRREL CAGE ROTORFluxtrol Inc.
Â
http://fluxtrol.com
ABSTRACT. Induction heating is the most progressive method for brazing of squirrel cage (SC) type rotors of electric motors. Frequencies from 3 to 10 kHz are typically being used for brazing of relatively large rotors (diameter more than 200 mm). If the ring thickness exceeds its height, flat single or two-turn inductors with concentrator are located under the ring instead of the round coil surrounding the ring. The rotor is standing on the top of the coil providing high pressure onto the joint components; a gap between the coil and ring is minimal and constant during the heating process.
This study describes a modified system with concentrator made of magnetic composite Fluxtrol 100. Frequency was much higher (around 50 kHz) than traditionally used (3-10 kHz). Electromagnetic and thermal coupled simulation with Flux 2D used to compare the process parameters and temperature distribution dynamics at 3 and 50 kHz. It was found that at higher frequency the brazing quality and time are approximately the same as at lower frequency. Electrical efficiency is slightly higher at 50 kHz while the coil current is significantly lower. Computer simulation at different powers showed that for a larger rotor the minimum required power is 70-75 kW. At lower power brazing time quickly increases and at 50 kW reaches 16 min instead of 5 min at 75 kW. Electrodynamic forces between the coil and rotor at 75 kW equal to 250 N at 50 kHz and almost 950 N at 3 kHz.
Thermal simulation of the coil proved that the maximum temperature of Fluxtrol 100 concentrator is below 200 C, which is acceptable for this material. Experimental and then industrial tests confirmed the results of simulation.
Design and Fabrication of Inductors for Induction Heat TreatingFluxtrol Inc.
Â
FOR INDUCTION MELTING AND MASS HEATING, the early induction heating coils
were manufactured from copper tubing wrapped in multiple turns around a mandrel. The first induction heat treating coils were developed for
crankshaft hardening in the 1930s (Fig. 1, 2) (Ref 1–4). Unlike the melting and mass heating
coils, the heat treating induction coils were machined. These inductors consisted of two
parts with a hinge on one side that would open and shut around the crankshaft journal. Quench holes were drilled on the inner diameter of the induction coil to deliver quench to the part afterheating. This pioneering development was the culmination of many years of hard work by a large team and clearly demonstrated the different requirements for induction heat treating as compared to melting and mass heating.
Copyright 2014, ASM International, www.asminternational.org. This article was published in ASM Handbook, Volume 4C: Induction Heating and Heat Treatment and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this article for a fee or for commercial purposes, or modification of the content of this article is prohibited.
Copyright 2014, ASM International, www.asminternational.org. This article was published in ASM Handbook, Volume 4C: Induction Heating and Heat Treatment and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this article for a fee or for commercial purposes, or modification of the content of this article is prohibited.
SIMULATION OF INDUCTION SYSTEM FOR BRAZING OF SQUIRREL CAGE ROTORFluxtrol Inc.
Â
http://fluxtrol.com
ABSTRACT. Induction heating is the most progressive method for brazing of squirrel cage (SC) type rotors of electric motors. Frequencies from 3 to 10 kHz are typically being used for brazing of relatively large rotors (diameter more than 200 mm). If the ring thickness exceeds its height, flat single or two-turn inductors with concentrator are located under the ring instead of the round coil surrounding the ring. The rotor is standing on the top of the coil providing high pressure onto the joint components; a gap between the coil and ring is minimal and constant during the heating process.
This study describes a modified system with concentrator made of magnetic composite Fluxtrol 100. Frequency was much higher (around 50 kHz) than traditionally used (3-10 kHz). Electromagnetic and thermal coupled simulation with Flux 2D used to compare the process parameters and temperature distribution dynamics at 3 and 50 kHz. It was found that at higher frequency the brazing quality and time are approximately the same as at lower frequency. Electrical efficiency is slightly higher at 50 kHz while the coil current is significantly lower. Computer simulation at different powers showed that for a larger rotor the minimum required power is 70-75 kW. At lower power brazing time quickly increases and at 50 kW reaches 16 min instead of 5 min at 75 kW. Electrodynamic forces between the coil and rotor at 75 kW equal to 250 N at 50 kHz and almost 950 N at 3 kHz.
Thermal simulation of the coil proved that the maximum temperature of Fluxtrol 100 concentrator is below 200 C, which is acceptable for this material. Experimental and then industrial tests confirmed the results of simulation.
2 Fluxtrol Sample Induction Heating InstallationsFluxtrol Inc.
Â
http://fluxtrol.com
Typical Induction Installation,
Review of Various Induction Machine Types, Block Diagrams of Process and Equipment Required, Generators, Frequesncy Variations, and more.
ASM 2013 Fluxtrol Presentation - Enhancing Inductor Coil ReliabilityFluxtrol Inc.
Â
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.
Increasing Inductor Lifetime by Predicting Coil Copper Temperatures PaperFluxtrol Inc.
Â
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.
Optimization Potential of Induction Heating Systems by Stefan Schubotz and Ha...Fluxtrol Inc.
Â
As published in Heat Processing (March 2015).
Depending on workpiece and process parameters, induction heating of components requires a certain amount of power. By simulation, experiments and experience, this needed energy can be well anticipated and enables the dimensioning of the converter. Basically, cost of the converter increases with rising provided power. Due to increasing energy expenses, efficiency of the system plays an important role. In this article, the influences of different process parameters on the efficiency of an example are investigated and valuable potential for improvement is demonstrated, so that the heating process is implemented with minimum converter power.
Increasing Inductor Lifetime by Predicting Coil Copper Temperatures PresentationFluxtrol Inc.
Â
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.
Chapter 5: Magnetic Flux Control for Induction Heating SystemsFluxtrol Inc.
Â
http://fluxtrol.com
Chapter 5: Magnetic Flux Control for Induction Heating Systems
Includes: Magentic Flux Concentrators, Process Improvements, Production Efficiencies, Simulation and Design.
Characterization of Carbon Fiber Reinforced Thermoplastics for Induction Proc...Fluxtrol Inc.
Â
Characteristics of Induction heating Carbon Fiber-Reinforced Thermoplastic (CFRT):
-Electrical Resistivity Determination of two specific CFRT’s
-Direction-specific by four-point method
-Equivalent resistivity by impedance method
-Thermal behavior of the studied materials
-Electromagnetic computer simulation of induction heating a lap joint.
-Different coil designs examined
-Current flow with resistivity differences examined
Chapter 6: Fluxtrol Materials on Induction CoilsFluxtrol Inc.
Â
http://fluxtrol.com
Chapter 6: Fluxtrol Materials on Induction Coils
Includes: 37 Fact Filled Slides of Process Improvement Technology and Materials utilizing Fluxtrol's 30 Years of Industry Serving Experience and Advanced Products.
MAGNETIC FLUX CONTROL IN INDUCTION INSTALLATIONSFluxtrol Inc.
Â
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.
Chapter 0: Fluxtrol Introduction to Induction Heating Technology and Magnetic...Fluxtrol Inc.
Â
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)
Magnetic Flux Controllers in Induction Heating and Melting by Robert Goldstei...Fluxtrol Inc.
Â
MAGNETIC FLUX CONTROLLERS are
materials other than the copper coil that are used
in induction systems to alter the flow of the magnetic
field. Magnetic flux controllers used in
power supplying components are not considered
in this article.
Magnetic flux controllers have been in existence
since the development of the induction
technique. Michael Faraday used two coils of
wire wrapped around an iron core in his experiments
that led to Faraday’s lawof electromagnetic
induction, which states that the electromotive
force (emf) induced in a circuit is directly proportional
to the time rate of change of the magnetic
flux through the circuit. After the development
of the induction principle, magnetic flux controllers,
in the form of stacks of laminated steel, found
widespread use in the development of transformers
for more efficient transmission of energy
(Ref 1, 2).
Magnetic cores gained widespread use in the
transformer industry because they increased
the amount of magnetic flux produced with
the same alternating current. The higher the
magnetic flux, the higher the emf, which results
in an increase in energy transfer efficiency from
the primary winding to the secondary winding.
Similar to transformers, magnetic cores were
used on early furnaces for induction melting
(Ref 1, 2). The benefits of magnetic flux controllers
vary depending on the application. For
induction heating, magnetic flux controllers can
provide favorable and unfavorable paths for magnetic
flux to flow, resulting in increased heating in
desired areas and reduced the heating in undesirable
areas, respectively.Magnetic flux controllers
are not used in every induction heating application,
but their use has increased (Ref 3, 4).
Copyright 2014, ASM International, www.asminternational.org. This article was published in ASM Handbook, Volume 4C: Induction Heating and Heat Treatment and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this article for a fee or for commercial purposes, or modification of the content of this article is prohibited.
Chapter 1B: Fluxtrol Basics of Induction Techniques Part 2Fluxtrol Inc.
Â
http://fluxtrol.com
Chapter 1B: Fluxtrol Basics of Induction Techniques Part 2.
Review of Basics of Induction Heating and Hardening, Computer Simulation Models, Electrodynamic Forces, and more.
Magnetic FLux Control in Induction Systems - Fluxtrol Heat Processing Paper Fluxtrol Inc.
Â
By Dr. Valentin Nemkov - Fluxtrol Inc.
Magnetic flux controllers are widely used in induction heating systems for concentration, shielding or redistribution of
the magnetic field which generates power in the part to be heated. Controllers, made of Soft Magnetic Composites
(SMC), provide accurate heat pattern control, improve parameters of inductors and performance of the entire installation.
In melting systems, especially in the case of vacuum furnaces, cold crucible and other specialty furnaces, the magnetic
control can provide large energy savings, magnetic field shielding, shorter melting cycles and optimized field distribution
for enhancement of the metallurgical processes. Due to the diversity of applications, service conditions of controllers
are very different including very severe cases. Mechanical, magnetic, electrical, thermal and other properties must be
considered in design and application of SMC. This article describes properties and performance of SMC typically used
in induction heating technology. Several presented case stories are based on more than 20 years of R&D and practical
experience of scientists and practitioners at Fluxtrol, Inc. Presented material may be interesting not only for induction
heating community but also for all people using AC magnetic fields in technological processes.
MAGNETIC FLUX CONTROL IN INDUCTION INSTALLATIONSFluxtrol Inc.
Â
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.
Paul J. Boudreaux Consider a Mixed Analog/Digital/MEMsssusercf6d0e
Â
Heat spreaders with high K values attached to the chip can help alleviate lateral DT problems. Placing the system or components into a forced isothermal environment also reduces DT, dT/dt and CTE related problems. Severing the thermomechanical heat path reduces or eliminates shock and vibration from entering the system while reducing weight.
2 Fluxtrol Sample Induction Heating InstallationsFluxtrol Inc.
Â
http://fluxtrol.com
Typical Induction Installation,
Review of Various Induction Machine Types, Block Diagrams of Process and Equipment Required, Generators, Frequesncy Variations, and more.
ASM 2013 Fluxtrol Presentation - Enhancing Inductor Coil ReliabilityFluxtrol Inc.
Â
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.
Increasing Inductor Lifetime by Predicting Coil Copper Temperatures PaperFluxtrol Inc.
Â
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.
Optimization Potential of Induction Heating Systems by Stefan Schubotz and Ha...Fluxtrol Inc.
Â
As published in Heat Processing (March 2015).
Depending on workpiece and process parameters, induction heating of components requires a certain amount of power. By simulation, experiments and experience, this needed energy can be well anticipated and enables the dimensioning of the converter. Basically, cost of the converter increases with rising provided power. Due to increasing energy expenses, efficiency of the system plays an important role. In this article, the influences of different process parameters on the efficiency of an example are investigated and valuable potential for improvement is demonstrated, so that the heating process is implemented with minimum converter power.
Increasing Inductor Lifetime by Predicting Coil Copper Temperatures PresentationFluxtrol Inc.
Â
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.
Chapter 5: Magnetic Flux Control for Induction Heating SystemsFluxtrol Inc.
Â
http://fluxtrol.com
Chapter 5: Magnetic Flux Control for Induction Heating Systems
Includes: Magentic Flux Concentrators, Process Improvements, Production Efficiencies, Simulation and Design.
Characterization of Carbon Fiber Reinforced Thermoplastics for Induction Proc...Fluxtrol Inc.
Â
Characteristics of Induction heating Carbon Fiber-Reinforced Thermoplastic (CFRT):
-Electrical Resistivity Determination of two specific CFRT’s
-Direction-specific by four-point method
-Equivalent resistivity by impedance method
-Thermal behavior of the studied materials
-Electromagnetic computer simulation of induction heating a lap joint.
-Different coil designs examined
-Current flow with resistivity differences examined
Chapter 6: Fluxtrol Materials on Induction CoilsFluxtrol Inc.
Â
http://fluxtrol.com
Chapter 6: Fluxtrol Materials on Induction Coils
Includes: 37 Fact Filled Slides of Process Improvement Technology and Materials utilizing Fluxtrol's 30 Years of Industry Serving Experience and Advanced Products.
MAGNETIC FLUX CONTROL IN INDUCTION INSTALLATIONSFluxtrol Inc.
Â
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.
Chapter 0: Fluxtrol Introduction to Induction Heating Technology and Magnetic...Fluxtrol Inc.
Â
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)
Magnetic Flux Controllers in Induction Heating and Melting by Robert Goldstei...Fluxtrol Inc.
Â
MAGNETIC FLUX CONTROLLERS are
materials other than the copper coil that are used
in induction systems to alter the flow of the magnetic
field. Magnetic flux controllers used in
power supplying components are not considered
in this article.
Magnetic flux controllers have been in existence
since the development of the induction
technique. Michael Faraday used two coils of
wire wrapped around an iron core in his experiments
that led to Faraday’s lawof electromagnetic
induction, which states that the electromotive
force (emf) induced in a circuit is directly proportional
to the time rate of change of the magnetic
flux through the circuit. After the development
of the induction principle, magnetic flux controllers,
in the form of stacks of laminated steel, found
widespread use in the development of transformers
for more efficient transmission of energy
(Ref 1, 2).
Magnetic cores gained widespread use in the
transformer industry because they increased
the amount of magnetic flux produced with
the same alternating current. The higher the
magnetic flux, the higher the emf, which results
in an increase in energy transfer efficiency from
the primary winding to the secondary winding.
Similar to transformers, magnetic cores were
used on early furnaces for induction melting
(Ref 1, 2). The benefits of magnetic flux controllers
vary depending on the application. For
induction heating, magnetic flux controllers can
provide favorable and unfavorable paths for magnetic
flux to flow, resulting in increased heating in
desired areas and reduced the heating in undesirable
areas, respectively.Magnetic flux controllers
are not used in every induction heating application,
but their use has increased (Ref 3, 4).
Copyright 2014, ASM International, www.asminternational.org. This article was published in ASM Handbook, Volume 4C: Induction Heating and Heat Treatment and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this article for a fee or for commercial purposes, or modification of the content of this article is prohibited.
Chapter 1B: Fluxtrol Basics of Induction Techniques Part 2Fluxtrol Inc.
Â
http://fluxtrol.com
Chapter 1B: Fluxtrol Basics of Induction Techniques Part 2.
Review of Basics of Induction Heating and Hardening, Computer Simulation Models, Electrodynamic Forces, and more.
Magnetic FLux Control in Induction Systems - Fluxtrol Heat Processing Paper Fluxtrol Inc.
Â
By Dr. Valentin Nemkov - Fluxtrol Inc.
Magnetic flux controllers are widely used in induction heating systems for concentration, shielding or redistribution of
the magnetic field which generates power in the part to be heated. Controllers, made of Soft Magnetic Composites
(SMC), provide accurate heat pattern control, improve parameters of inductors and performance of the entire installation.
In melting systems, especially in the case of vacuum furnaces, cold crucible and other specialty furnaces, the magnetic
control can provide large energy savings, magnetic field shielding, shorter melting cycles and optimized field distribution
for enhancement of the metallurgical processes. Due to the diversity of applications, service conditions of controllers
are very different including very severe cases. Mechanical, magnetic, electrical, thermal and other properties must be
considered in design and application of SMC. This article describes properties and performance of SMC typically used
in induction heating technology. Several presented case stories are based on more than 20 years of R&D and practical
experience of scientists and practitioners at Fluxtrol, Inc. Presented material may be interesting not only for induction
heating community but also for all people using AC magnetic fields in technological processes.
MAGNETIC FLUX CONTROL IN INDUCTION INSTALLATIONSFluxtrol Inc.
Â
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.
Paul J. Boudreaux Consider a Mixed Analog/Digital/MEMsssusercf6d0e
Â
Heat spreaders with high K values attached to the chip can help alleviate lateral DT problems. Placing the system or components into a forced isothermal environment also reduces DT, dT/dt and CTE related problems. Severing the thermomechanical heat path reduces or eliminates shock and vibration from entering the system while reducing weight.
Review Study and Importance of Micro Electric Discharge Machiningsushil Choudhary
Â
Micro EDM process is one of the micro- machining processes. It can be used to machine micro features and
makes a micro parts. There is a huge demand in the production of microstructures by a non-traditional method
which known as Micro-EDM. Micro-EDM process is based on the thermoelectric energy between the workpiece
and an electrode. Micro-EDM is a newly developed method to produce micro-parts which in the range of
50 ÎĽm -100 ÎĽm. Micro-EDM is an efficient machining process for the fabrication of a micro-metal hole with
various advantages resulting from its characteristics of non-contact and thermal process. A pulse discharges
occur in a small gap between the work piece and the electrode and at the same time removes the unwanted
material from the parent metal through the process of melting and vaporization. This paper describes the
importance, parameters, principle, difference between Macro and micro EDM, applications and advantages of ÎĽ-
EDM and discuss about the literature reviews based on performance measure in micro- EDMP process.
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
Â
call for paper 2012, hard copy of journal, research paper publishing, where to publish research paper,
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
ASM 2013 Fluxtrol Paper - Innovations in Soft Magnetic Composites and their A...Fluxtrol Inc.
Â
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.
Thermal Stress Analysis of Electro Discharge MachiningIJESFT
Â
Procedures and results of experimental work to find thermal stress analysis in electric discharge machined surfaces are presented. In this study, an axisymmetric thermo-physical FEA model for the simulation of single sparks machining during electrical discharge machining (EDM) process is shown. This model has been solved using ANSYS 14.0 software. A transient thermal analysis assuming a Gaussian distribution heat source with temperature-dependent material properties is used to investigate the stress analysis based on temperature distribution. The effect on significant machining parameters (Gap current – Gap voltage) on aforesaid responses had been investigated and found that the stresses sharply changes with the parameters [1].
The FEA model is used to study the relation between these parameters and maximum temperature attended at the end of cycle which is further used to find residual stress produced at the end of cooling cycle. To find residual stresses in the work piece during EDM, the temperature distribution at the end of pulse duration in the work piece has to be estimated [2]
High residual thermal stresses are developed on the surfaces of electric discharge machined parts because of the high temperature gradients generated at the gap during electrical discharge machining (EDM) in a small heat-affected zone. These thermal stresses can be responsible for micro-cracks, decrease in fatigue life and strength and possibly catastrophic failure. The results of the analysis show high temperature gradient zones and the regions of large stresses where, sometimes, they exceed the material yield strength. A transient thermal analysis assuming a Gaussian distribution heat can be used to investigate the Stress analysis.
ethodology for determining the parameters of hightemperature superconducting...IJECEIAES
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This paper substantiates a new adaptive method for determining parameters of high-temperature superconducting power transformers with current limiting function. The main focus is the design of current-limiting superconducting windings in the light of new restrictions on current density, magnetic induction, critical current and critical temperature. The presented method considers the nature of alternating current (AC) losses in a superconductor under nominal operating conditions, features of the dielectric medium (liquid nitrogen), as well as the reduced values of the short-circuit voltage (0.5 to 1.5%). The main design features of high-temperature superconducting (HTS) transformers are specified, and a prototype of a three-phase HTS transformer of 63 kVA with a short-circuit current limiting function is developed. It is shown that HTS units have some advantages over conventional transformers: a 90 to 95% active losses reduction, short-circuit current limitation function, explosion and fire safety, a 60% reduction in weight and size, and increased efficiency (up to 99.8%). Experimental studies confirm that the short-circuit current limitation function is safe and efficient. It is demonstrated that during the short-circuit current limitation, significant heat flows occur on the windings, which should not exceed the critical value above which the superconductor could not return to the superconducting state by itself.
* 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
Complete Coverage on High velocity forming methods also known as high energy rate forming processes HVF and HERF. Very useful for mechanical engineering students and teachers.. Explosive forming, magnetic pulse forming, hydro forming, electro hydro forming discussed.
Magneto Optic Current Transformer Technology (MOCT)IOSRJEEE
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An accurate electric current transducer is a key component of any power system instrumentation. To measure currents power stations and substations conventionally employ inductive type current transformers .For high voltage applications, porcelain insulators and oil-impregnated materials have to be used to produce insulation between the primary bus and the secondary windings. The insulation structure has to be designed carefully to avoid electric field stresses, which could eventually cause insulation breakdown. The electric current path of the primary bus has to be designed properly to minimize the mechanical forces on the primary conductors for through faults. The reliability of conventional high-voltage current transformers have been questioned because of their violent destructive failures which caused fires and impact damage to adjacent apparatus in the switchyards, electric damage to relays, and power service disruptions. In addition to the concerns, with the computer control techniques and digital protection devices being introduced into power systems, the conventional current transformers have caused further difficulties, as they introduce electromagnetic interference through the ground loop into the digital systems. Magneto-optical current transformer(MOCT)technology provides a solution for many of the above mentioned problems. The MOCT measures the electric current by means of Faraday Effect that is the orientation of polarized light rotates under the influence of the magnetic fields and the rotation angle is proportional to the strength of the magnetic field component in the direction of optical path. MOCT is a passive optical current transducer which uses light to accurately measure current on high voltage systems and determines the rotation angle & converts it into a signal of few volts proportional to the current
Similar to New Magnetodielectric Materials for Magnetic Flux Control (20)
Hot Hydroforging of Lightweight Bilateral Gears and Hollow ProductsFluxtrol Inc.
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Feasibility of making lightweight powertrain products with hot hydroforging of steel/low density material hybrid billets is explored. A bimaterial billet is designed such that a steel wall encloses a low density core 100%. Furthermore the low density core is selected among the materials that have lower melting or softening temperature than steel such as aluminum and glass. In hot hydroforging the bimaterial billet is heated to 1000-1200 C range similar to the conventional hot forging of steel. However, in hot hydroforging the core is in liquid or viscous state while steel shell is in solid state similar to the conventional hydroforming. During hot hydroforging the viscous/liquid core has negligible resistance to flow thereby providing a uniform hydrostatic pressure inside the steel and enabling a uniform deformation of the solid steel wall.
Modeling of the Heating Sequences of Lightweight Steel/Aluminum Bimaterial Bi...Fluxtrol Inc.
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Paper by:
Robert Goldstein Fluxtrol Inc., Auburn Hills, MI, USA
Bulent Chavdar Eaton, Southfield, MI, USA
Lynn Ferguson DANTE Solutions Inc., Cleveland, OH, USA
ABSTRACT:
In this paper, the concept studied is hot forged from a bimetal
billet, which is a steel tube press fit with a solid aluminum
core and welded shut with steel end caps. For the experimental
part of the studies Al 7075 was selected as the core material
due to its high strength to weight ratio and 1020 steel was
selected because of its availability as a tube. Induction heating
was selected as the heating method for bimetal forging. This
is due to the ability of induction heating to rapidly heat the
steel layer. Successful bimetal forging of a closed vessel
requires the steel layer to be in the austenite phase prior to the
aluminum reaching high temperatures to prevent
compromising the weld seams. Modeling of the induction
heating process is complex due to the dimensional movement
of components during the process. A method was developed
to accurately model the induction heating process and predict
power requirements. The method will be described and the
results of the models will be compared to experimental
findings. The forming process will be discussed in another
paper at the conference. The simulation presented is for solid
state forging of a steel aluminum billet, but the method for
modeling the process is the same for hot hydroforging or other
material combinations.
Fluxtrol Testimonial - Peak Manufacturing Induction Heat Treat LineFluxtrol Inc.
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Fluxtrol and Peak Manufacturing of Pleasant Lake, Michigan recently had the good fortune of working together on the development of Peak's first induction heat treating line at their Secondary Machining and Cold Forming Manufacturing Company.
Fluxtrol appreciates the kind words and would like to thank everyone at Peak who was involved in the project. It was truly our pleasure.
Torsional Fatigue Performance of Induction Hardened 1045 and 10V45 SteelsFluxtrol Inc.
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Microalloying of medium carbon bar steels is a common
practice for a number of traditional components; however, use
of vanadium microalloyed steels is expanding into
applications beyond their original designed use as controlled
cooled forged and hot rolled products and into heat treated
components. As a result, there is uncertainty regarding the
influence of vanadium on the properties of heat treated
components, specifically the effect of rapid heat treating such
as induction hardening. In the current study, the torsional
fatigue behavior of hot rolled and scan induction hardened
1045 and 10V45 bars are examined and evaluated at effective
case depths of 25, 32, and 44% of the radius. Torsional fatigue
tests were conducted at a stress ratio of 0.1 and shear stress
amplitudes of 550, 600, and 650 MPa. Cycles to failure are
compared to an empirical model, which accounts for case
depth as well as carbon content.
Fluxtrol's "Best Practice for Design and Manufacturing of Heat Treating Induc...Fluxtrol Inc.
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With the use of good design practices, one can improve coil longevity and improve production quality. By eliminating failure points in the initial design, proper material selection, improved cooling and proper magnetic flux control, induction tooling life can be increased. Computer simulation has been proven to be an effective tool for predicting not only electromagnetic parameters of a designed system, but also heat patterns in a given part and in the induction coil itself. When a coil has magnetic flux controllers present, their influence may also be predicted by computer simulation. With an extensive library of published case studies in induction coil design and performance evaluations, we are confident with the use of these tools and proper coil geometries and implementation, production life and quality can be improved on most induction heat treating inductors. These design practices have been used by the authors for over 20 years with proven results. A case is examined of a CVJ stem hardening coil, in which the principles discussed can be applied to most other hardening coils.
Hot Hydroforging for Lightweighting Presentation IDE 2015 Fluxtrol Inc.
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Bimaterial products can be hot forged from a bimaterial billet where the steel shell encloses the lightweight core fully. A bimaterial billet can be forged in solid state however a better forging quality can be achieved if the core material is viscous thereby providing uniform hydrostatic pressure to steel shell during forging similar to a hydroforming process. However, the similarity only pertains to the hydrostatic pressure developed inside the deforming billet not to the process temperatures. While hydroforming is done at room temperatures the hot hydroforging is done at temperatures greater than 1000C enabling deformation of steel into intricate topologies without a fracture. Other differences between the hydroforming and hot hydroforging are that the amount of fluid is constant in hot hydroforging and the fluid may solidify and become an integral part of the product after forging and cooling. The lightweight core material will need to have a lower melting or softening temperature than the steel for Hot Hydroforging. Aluminum, magnesium, and glass are such candidate lightweight materials.
Recognizing and Eliminating Flux Concentrator FailuresFluxtrol Inc.
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http://fluxtrol.com
Overview:
• What are the failure modes of a flux concentrator?
• How do we improve the design to prevent the failure in the future?
• Examples of coil lifetime improvement by proper use of flux
concentrators.
Specification and Use of a Flux ConcentratorFluxtrol Inc.
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http://fluxtrol.com
Overview:
Basics of Magnetic Flux Control
Effect of Flux Controllers on Different Coil Styles
Materials for Magnetic Flux Control
Influence of Magnetic Permeability
Selecting the Proper Flux Concentrator
Crankshaft Hardening Inductors
ASM 2013 Fluxtrol Presentation - Innovations in Soft Magnetic Composites and ...Fluxtrol Inc.
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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.
Presentation on Effect of Spray Quenching Rate on Distortion and Residual Str...Fluxtrol Inc.
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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.
Effect of Spray Quenching Rate on Distortion and Residual Stresses during Ind...Fluxtrol Inc.
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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.
Modeling and Optimization of Cold Crucible Furnaces for Melting MetalsFluxtrol Inc.
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http://fluxtrol.com
Cold Crucible Furnaces (CCFs), widely used in multiple special applications of
melting metals, oxides, glasses and other materials [1], are essentially 3D devices and their modeling is a complicated task. Multiple studies of CCFs have been made for their
optimization, but their electrical efficiency is still low; for metals approximately 25-30% andeven lower. Fluxtrol, Inc., made an extensive study of electromagnetic processes of CCFs using computer simulation and laboratory tests. This study showed that electrical efficiency of CCFs may be strongly improved by means of optimal design of the whole system with use of magnetic flux controllers. Theoretical results had been confirmed by laboratory tests on mockups and by industrial tests with real melting processes. The presentation contains a description of the computer modeling procedure and major findings. They form a basis for optimal design of electromagnetic systems of CCFs.
MODELING AND OPTIMIZATION OF COLD CRUCIBLE FURNACES FOR MELTING METALSFluxtrol Inc.
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http://fluxtrol.com
Cold Crucible Furnaces (CCFs), widely used in multiple special applications of
melting metals, oxides, glasses and other materials [1], are essentially 3D devices and their
modeling is a complicated task. Multiple studies of CCFs have been made for their
optimization, but their electrical efficiency is still low; for metals approximately 25-30% and
even lower. Fluxtrol, Inc., made an extensive study of electromagnetic processes of CCFs
using computer simulation and laboratory tests. This study showed that electrical efficiency of
CCFs may be strongly improved by means of optimal design of the whole system with use of
magnetic flux controllers. Theoretical results had been confirmed by laboratory tests on
mockups and by industrial tests with real melting processes. The presentation contains a
description of the computer modeling procedure and major findings. They form a basis for
optimal design of electromagnetic systems of CCFs.
GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using Deplo...James Anderson
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New Magnetodielectric Materials for Magnetic Flux Control
1. Heavy Wall Pipe Seam Annealing Page 1 HES 2004
New Magnetodielectric Materials for Magnetic Flux Control
Mr. Robert T. Ruffini
Fluxtrol Manufacturing, Inc.
1388 Atlantic Blvd., Auburn Hills, MI 48326 USA
Phone +1 248 393 2202, www.fluxtrol.com
Dr. Valentin Nemkov, Dr. Nina Vyshinskaya
Centre for Induction Technology, Inc.
1388 Atlantic Blvd., Auburn Hills, MI 48326 USA
Phone +1 248 393 2200, www.induction.org
ABSTRACT
Magnetodielectric materials play an important role in improvement of induction
systems for heat treatment, brazing, soldering, sealing and other technologies. This
presentation is a continuation of the report made at HIS-01. Current report shows the
results of development of new magnetodielectric materials for magnetic flux control and
intensive study of their properties.
Presentation contains information on new MagnetoDielectric Materials (MDM’s)
Fluxtrol 25, Fluxtrol 50 and a third new material developed specifically for low
frequency (less than 10 kHz) applications. It is shown that some magnetodielectric
materials have significant property anisotropy. This anisotropy may be beneficially used
for optimal design of magnetic flux controllers. A presentation is accompanied by table-
top exhibition with samples of magnetodielectric materials and inductors with magnetic
flux controllers.
INTRODUCTION
There are four main families of electromagnetic applications where soft magnetic
materials are used: electromechanical devices, low frequency industrial applications, high
frequency industrial applications, and telecommunications. Figure 1 shows the common
frequency ranges of different electromagnetic applications. The requirements for soft
magnetic materials are quite different depending upon the type of application.
Electromechanical devices consist mainly of electrical motors, relays, solenoid and
drives, which generally work at frequencies between DC and several hundred hertz.
These products are typically relatively high volume (thousands of parts) and warrant
specific tooling for manufacturing. The main requirements to materials in
electromagnetic devices are high permeability, high saturation flux density, low core
losses (if AC) and good mechanical strength. The core losses for these materials are
typically due to hysteresis losses.
The low frequency industrial applications that utilize soft magnetic materials are
typically large induction installations for melting, mass heating, forging, etc. In these
applications, the processing temperature is high and the magnetic materials must be in
close proximity to the load. The frequency range for these applications is typically
between 50 Hz and 3 kHz. The number of installations of a given type is relatively small
due to the huge production rates and the shape of soft magnetic materials required varies.
The main requirements to materials in low frequency industrial applications are high
2. Heavy Wall Pipe Seam Annealing Page 2 HES 2004
permeability, high saturation flux density, low core losses and good temperature
resistance.
Communications applications often use soft magnetic materials for radio electronics
transformers, chokes, antennas and other devices. The frequency range for these
applications is above 500 kHz to several GHz. These applications typically are very high
volume and the shapes used are relatively simple.
The high frequency industrial applications that use soft magnetic materials consist
mainly of a wide variety of induction heating processes including heat treating, small
quantity or low conductive material (ie glass) melting, preheating, joining, etc. This
family of applications is much more diverse than the low frequency industrial
applications. In addition, each of these applications require special know-how for proper
electromagnetic system design. The following sections discuss the role of soft magnetic
materials, the materials available and considerations for their use that must be taken into
account when working in this area of application with special attention paid to
magnetodielectric materials.
Frequency Ranges for Different EM Applications
100000
10000 Communications
1000
High Frequency
Frequency (kHz)
100
10 Low Frequency
Induction
1
Electromechanical
0.1
Devices
0.01
Applications
Figure 1 Frequency ranges for electromagnetic applications
ROLE OF MAGNETIC FLUX CONTROLLERS
Magnetic flux controllers are a powerful tool in induction heating technology [1].
Recently, better understanding of their role in different induction heating systems has
been obtained through a comprehensive study using computer simulation and
experiments at Centre for Induction Technology, Inc. The results of this study show that
the proper use of a magnetic flux controller is always beneficial in an induction heating
system [1]. They can play different roles in induction heating installations and in various
applications are being named as concentrators, controllers, diverters, cores, impeders or
screens.
Magnetic flux controllers may provide the following effects:
ď‚· improvement of the induction coil and process efficiency;
ď‚· improvement of the coil power factor;
ď‚· protection of machine components and certain workpiece zones against unwanted
heating;
3. Heavy Wall Pipe Seam Annealing Page 3 HES 2004
ď‚· precise control of the magnetic field and the resulting heat pattern
ď‚· improvement in efficiency of the high frequency power supplying circuitry;
ď‚· elimination of external magnetic fields in close proximity to the coil.
In most real applications more than one of these benefits usually occur. For processes
such as case hardening, tempering or brazing where the results are very critical to
operating conditions of heating process, quality improvement is usually the most
important. Application of magnetic flux controllers strongly influences the power density
value and its distribution along the surface of the workpiece enabling faster heating and
better heat pattern control. In addition to improvements in metallurgical results and
physical properties of parts, heat pattern control allows you to control stresses and
strongly reduce part distortion.
To illustrate how magnetic flux controllers may be used in the optimal design of an
induction heating process, we’ll describe shortly a real world installation for stress
relieving of spiral welded heavy walled steel pipe for the oil and gas industry. The
induction heating user purchased an installation for weld seam annealing on large
diameter seam annealing (T>900 C) after arc spiral welding (figure 2). The unit was
working fine for its intended application. Then, the specifications for the tube heat
treatment were changed. Instead of full annealing of the weld seam, the process required
was specified as a high temperature stress relieving (550-650 C) and the Heat Affected
Zone (HAZ) was widened from 30 mm to 60 mm.
stluseR edahS roloC Color Shade Results
s uisleC . geD er utarepmeT : ytit na uQ Quantity : Temperature Deg. Celsius
0 :) geD( esa hP 71 : ).s( emiT Time (s.) : 17 Phase (Deg): 0
r ol oC / elacS Scale / Color
75 2 7 3. 27 / 2 02 3.3 2 23.3202 / 72.37257
3 9 42 4.1 2 1 / 7 5 27 3.2 7 72.37257 / 121.42493
92 7 74. 07 1 / 39 4 24. 12 1 121.42493 / 170.47729
66 9 25. 91 2 / 92 7 74. 07 1 170.47729 / 219.52966
30 2 85. 86 2 / 66 9 25. 91 2 219.52966 / 268.58203
4 4 36. 71 3 / 30 2 85. 86 2 268.58203 / 317.6344
4 7 68 6.6 6 3 / 4 4 36. 71 3 317.6344 / 366.68674
11 9 37. 51 4 / 47 6 86. 66 3 366.68674 / 415.73911
74 1 97. 46 4 / 11 9 37. 51 4 415.73911 / 464.79147
78 3 48. 31 5 / 74 1 97. 46 4 464.79147 / 513.84387
81 6 98. 26 5 / 78 3 48. 31 5 513.84387 / 562.89618
55 8 49. 11 6 / 81 6 98. 26 5 562.89618 / 611.94855
29 0 00. 16 6 / 55 8 49. 11 6 611.94855 / 661.00092
82 3 50. 01 7 / 29 0 00. 16 6 661.00092 / 710.05328
56 5 01. 95 7 / 82 3 50. 01 7 710.05328 / 759.10565
20 8 51. 80 8 / 56 5 01. 95 7 759.10565 / 808.15802
Figure 2. Final temperature distribution for the weld seam stress relieving process
using the same coil as for weld seam annealing
When the user tried to set up the new process, they found two things: the heat affected
zone was too narrow and they were not able to get the inside of the weld seam up to the
specified temperature without overheating the surface and there was no space for a longer
coil. They tried slowing the process down significantly, but they were still unable to
meet the new heat treating specifications. The reason for their difficulties can be easily
explained using computer simulation. Figure 3 shows the color shade of the temperature
distribution at the end of the heating process and the temperature on the inner and outer
weld beads over the course of the process using their seam annealing inductor.
4. Heavy Wall Pipe Seam Annealing Page 4 HES 2004
Figure 3. Inner and outer weld bead temperature evolution for the existing stress
relieving process
Compared to the old process, the pipe is magnetic throughout the entire process so the
induced heat sources flowed only in a shallow surface layer of the workpiece. This
meant that the center of the workpiece was heated entirely by heat conduction from the
surface
Figure 4. Final temperature distribution and inner and outer weld bead temperature
evolution for the optimized coil and process
To provide the wider HAZ, the turns were separated. The best solution to get the
inside of the weld bead up to temperature is magnetic flux controller variation in the coil
length. Fluxtrol A magnetic flux concentrator was applied for this application. The initial
stage is a ramping to the maximum surface temperature and the full C-shape cross-
section is applied. After the maximum temperature is reached, we begin to cut back
some of the concentrator pole to hold the maximum temperature constant. More
concentrator is removed until the final stage is reached and we have no concentrator at
all. Figure 4 shows the temperature distribution in the weld seam area 6 seconds after the
5. Heavy Wall Pipe Seam Annealing Page 5 HES 2004
point has left the coil. Figure 4 also shows the temperature on the inner and outer weld
beads over the heating process. You can see that the temperature is uniform in thickness
and in width with the new design.
MATERIALS FOR MAGNETIC FLUX CONTROL
Requirements for magnetic flux contolling materials in induction heating processes
can be very severe in many cases. They must work in a very wide range of frequencies,
possess high permeabilities and saturation flux densities, have stable mechanical
properties and exhibit resistance to elevated temperatures from losses in the concentrator
and radiation from the heated part surface. In heat treating and brazing, the material must
withstand hot water attack, quenchants and active technological fluxes. Machinability is
also a very important property for successful application of flux controllers, because it
allows you to obtain the exact concentrator dimensions necessary to assure consistent
results and precise magnetic field control.
As was discussed above, there is a very wide range of requirements for the various
induction heating applications and therefore more than one magnetic flux controlling
material is required to cover the whole range. Three groups of magnetic materials may
be used for magnetic flux control: laminations, ferrites and MagnetoDielectric Materials
(MDM) [2]. Laminations have long been used in electromagnetic systems and their
abilities and limitations, especially in manufacturing and frequency, are well
documented. The use of ferrites relatively uncommon in induction heating due to very
low machinability, sensitivity to thermal shock, and low saturation flux density. MDM’s
are well suited to induction requirements and have the potential for use in the entire
application range.
Special Properties of MDM’s
MDM’s are an evolving material class and there is currently rapid progress in their
improvement and understanding. They have some special properties, that when properly
utilized, can lead to significant induction system parameter improvement. Two of these
properties that have not been adequately discussed before are electrical resistivity and
anisotropy.
MDM’s are a wide family of materials ranging from good dielectrics to traditional
powder metal magnetics. Electrical resistivity is an important parameter of the material
which is contradictory to magnetic permeability. The higher the permeability is, the
lower the electrical resistivity when using the same materials and manufacturing
technology. The nature and proper evaluation of electrical resistivity are rather
complicated. At DC current and 50/60 Hz there are only galvanic currents due to random
contact between individual metal particles and defects of insulation layers. The resulting
resistivity is non-linear with declining values as applied voltage is increased. This effect
is especially strong for high-resistive, low permeability materials. At high frequency
(hundreds kHz) additional capacitive currents can result in a higher value of measured
resistivity.
It is necessary to underline that electrical resistivity does not characterize correctly
losses in material. When using computer simulation, we calculate losses in concentrator
due to its electrical resistivity, those are only a fraction of total losses caused by
hysteresis and eddy-currents in individual particles of the composite. In properly
designed induction coils with concentrators, they are a small fraction of total magnetic
6. Heavy Wall Pipe Seam Annealing Page 6 HES 2004
losses. Proper understanding of electrical properties of MDM is essential for prediction of
its performance under application conditions.
Similar to electrical resistivity, anisotropy of MDM’s is also not well described in
literature. All pressed metal powder materials have certain anisotropy in mechanical,
electrical and magnetic properties. This anisotropy is caused by magnetic particle
alignment and deformation during the manufacturing process. Magnetic permeability is
minimal in direction of pressing and maximal in the perpendicular plane. For toroidal
parts, which are widely used in electronics, anisotropy does not play any role while for
induction heating applications it may be essential in many cases. Anisotropy may be
effectively used, especially in 3D magnetic fields in order to reduce field in less desirable
direction. The level of anisotropy depends on material composition, shape of particles
and pressure applied.
It is more pronounced in high-permeability materials such as Fluxtrol A and the new
low frequency material manufactured by Fluxtrol Manufacturing, Inc. The difference in
permeability may be up to two times. Besides permeability, other properties essential for
successful concentrator application are also directionally dependent including thermal
conductivity and magnetic losses. For advice related to anisotropy of materials, please
contact Fluxtrol Manufacturing, Inc.
MDM’s for Magnetic Flux Control
Since the HIS ’01 conference, Fluxtrol Manufacturing, Inc. has introduced 3 new
materials for magnetic flux control in induction systems. These new materials are
Fluxtrol 25, Fluxtrol 50, and a new low frequency material. The magnetization curves
for the main materials manufactured by Fluxtrol are shown in Figure 5. The curves of the
resulting relative magnetic permeability for these materials are shown in Figure 6.
B vs H
18000
16000
New LF
14000
Material
12000
Fluxtrol A
10000
B, Gs
8000 Fluxtrol 50
6000
Fluxtrol 25
4000
2000 Ferrotron 559
0
0 25 50 75 100 125 150 175 200 225
H, A/cm
Figure 5. Magnetization curves for MDM’s manufactured by Fluxtrol Manufacturing,
Inc.
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Permeability vs H
180
160
140
120 New LF
Permeability
Material
100 Fluxtrol A
80 Fluxtrol 50
60 Fluxtrol 25
40 Ferrotron
559
20
0
0 20 40 60 80 100 120 140 160 180 200
H, A/cm
Figure 6. Permeabilities of MDM’s manufactured by Fluxtrol Manufacturing, Inc.
The nomenclature for the new materials in the Fluxtrol family is based upon the
normal “working permeability” of the materials. The magnetic permeability of MDM’s
depends upon the magnetic field strength. The general trend is that the permeability
increases with field strength until reaching a maximum value and then the permeability
declines. For higher frequency MDM’s, this distribution is relatively smooth. The
“working permeability” is an average value of the permeability in the normal range of
field strengths the material was designed to work in.
Fluxtrol 25 is a material that was designed to replace Fluxtrol B in medium and high
frequency applications (20 kHz to 500 kHz). The magnetic properties of Fluxtrol 25 are
the same as those of Fluxtrol B, making it possible for direct replacement. Fluxtrol 25
has improved temperataure resistance (250 C long term and 300 C short term compared
to 200 C long term and 250 C short term for Fluxtrol B), making it more reliable in heavy
duty applications, while maintaining its excellent machinability.
Fluxtrol 50 is a material that was designed to fill a gap that was not currently covered
in Fluxtrol’s old product line. Fluxtrol 50 has high enough permeability for effective use
in low frequency applications (working permeability around 50, but it can also be used in
higher frequency applications (60 Hz to 500 kHz) and. Fluxtrol 50 has the same
temperature resistance as Fluxtrol 25. Fluxtrol 50 has very good machinability and is
relatively strong even in thin sections (1.5 – 2 mm).
The other new material that is currently available was designed for use in low
frequency applications, such as mass heating, melting and continuous casting. The new
low frequency material has a lower price than the materials in the Fluxtrol and Ferrotron
families. This makes it cost effective in most cases to use it as a replacement for
laminations.
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CONCLUSIONS
Induction applications provide many challenges for soft magnetic materials. These
applications are typically low volume and there is a great degree of variation in process
type and material requirements. This makes properties such as machinability and
chemical stability more important than in other electromagnetic applications.
MagnetoDielectric Materials (MDM’s) are a type of soft magnetic material that are
gaining increased acceptance in induction applications. They have special properties,
which make them very favorable for induction heating conditions. At the same time, the
specific features of these materials are not as well understood as for other soft magnetic
materials. Two of these properties, electrical resistivity and anisotropy, were discussed in
this paper.
Since HIS ’01, Fluxtrol Manufacturing, Inc. has introduced 3 new materials for
magnetic flux control in induction heating systems: Fluxtrol 25, Fluxtrol 50 and a new
material for low frequency applications. These new materials have superior properties to
other soft magnetic materials in many applications.
REFERENCES
[1] Ruffini, R. T., Nemkov, V. S., Goldstein, R. C. Magnetic Flux Controllers-New
Materials, New Opportunities. ASTRA 2003. November 3–6, 2003. Hyderabad, India
[2] Nemkov V.S., Goldstein, R. C., Ruffini, R. T. Soft Magnetic Powdered Metal
Materials for High Frequency Industrial Applications. PMTec 2001. May 13-17, 2001.
New Orleans, La-USA.