asm 2013 fluxtrol presentation - innovations in soft magnetic composites and their applications in...
DESCRIPTION
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.TRANSCRIPT
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Innovations in Soft Magnetic
Composites and their Applications
in Induction Systems
Dr. V. Nemkov, Dr. N. Vyshinskaya, R.T. Ruffini
R. Goldstein, C. Yakey
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Overview
• SMC for magnetic flux control in induction systems
• Properties of Fluxtrol materials
• Application technique for:
- Formable materials
- Solid materials
• Coating
• Impregnation
• Machining
Coil for axle hardening
with magnetic controller
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Materials for Flux Control
Fluxtrol Inc. produces 3 primary materials and 5 new
Primary products:
• Fluxtrol A
• Fluxtrol 50
• Ferrotron 559 H
New products:
• Alphaform LF, MF and HF
• Fluxtrol 100 (instead of Fluxtrol A)
• Fluxtrol LF (Low Frequency) Remelting of plasma
coated layer on a shaft
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Parameters of Primary Materials
Properties Units Ferrotron
559H Fluxtrol 50 Fluxtrol A
Density ± 2% g/cm3 5.9 6.1 6.6
Initial
Permeability - 16 36 63
Maximum
Permeability - 18 55 120
Saturation
Flux Density Tesla 1 1.5 1.6
Frequency Range kHz 10-3000 10-1000 1-50
Temp. Resistance
Long Term
Short Term
Celsius 250 250 250
300 300 300
Thermal
Conductivity W/cmK 0.04 0.06 0.2
Resistivity kOhmcm >15 0.5 0.5
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Parameters of New Materials Properties Units
Fluxtrol
100
Fluxtrol
LF
Alphaform
LF MF HF
Density
± 2% g/cm3 6.9 6.7 4.1 4.0 3.9
Initial
Permeability -- 80 80 11 9.8 8.8
Maximum
Permeability -- 130 165 13 10 9
Saturation
Flux Density Tesla 1.6 1.8 1.0 1.0 1.0
Frequency
Range kHz 0.05 - 50 0.05 - 3 1 - 80
10 -
450
20 -
3000
Temperature
Resistance Celsius 200 200 225 225 225
Thermal
Conductivity W/cm K 0.23 0.22 0.02 0.02 0.02
Resistivity kOhmcm 12.5 0.004 >15 >15 >15
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Alphaform Materials
• Developed by Alpha One on the
basis of magnetic particles with
a thermal-curing epoxy binder
• Material is formable when warm
• Can be used for quick & efficient
installation to coils with low
tolerances
• Three versions are available:
for high (HF), middle (MF)
and low (LF) frequencies
Tin packages with formable material
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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
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Alphaform Application for ID
Coils
Material easily fills internal
volumes providing good heat
transfer to water-cooled turns
Bare inductor Inductor with Alphaform MF
Heating steel pipe; same power settings; t = 6.0 sec
BARE ALPHAFORM
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Fluxtrol 100
Fluxtrol 100 created to
substitute Fluxtrol A
Advantages:
• Fluxtrol 100 has lower
anisotropy and its
performance is less
dependent on cutting
direction
• Higher thermal
conductivity
• Higher mechanical
strength
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.
P
erm
eab
ilit
y
Permeability vs. Field Strength
Field Strength, A/cm
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Fluxtrol 100 Application
Induction coils for rotational hardening of crankshafts. Concentrators are segmented to tolerate better the copper
extension during thermal cycles
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Water-Cooled Magnetic Templates
• With internal water cooling Fluxtrol controllers may be
used in hot environment
• Computer simulation and experiments confirmed that
water-cooled templates carrying high magnetic field can
work in close proximity to the hot body
Water-cooled
template
Dimensions 32.7 x 88 x 222 mm (1.3 x 3.5 x 8.75”)
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ELECTRICAL VARNISHES
Corrosion protection
Varnishes, paints & coatings
Electrical insulation
Varnishes, ceramic & nylon coating
Clean room requirements
Teflon coating
Aseptic (FDA standards)
Teflon coating
Material Coatings
CERAMIC COATING PTFE COATING
VARNISH COATING
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Teflon Coating
Teflon coating thickness can vary from several microns to 20 microns depending on coating type and technology
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Impregnation
• Impregnation consists in parts soaking in a special epoxy resin under vacuum
• Then resin penetrates into the open pores under applied pressure
• Resin polymerizes inside the pores
• Excess of resin is being removed from the surface
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Impregnation Results • Better mechanical properties and
machinability
• Lower surface and volumetric corrosion
• Excellent gluing of all the surfaces
• Magnetic properties don’t change
• Increase of electrical resistivity
• Depth of penetration depends upon the material type; e.g. for
Fluxtrol 50 it is app. 0.4”
Two impregnated samples glued with epoxy 50-3100 Light areas – impregnated
layer
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Sample of Fluxtrol 100 with Stainless Steel Inserts for Bolts M5
Close view of steel insert
Inserts have been screwed into the material
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Fluxtrol Machining
FLUXTROL 100 DETAILS MADE W/ STRD MILL TOOLS
• Materials may be easily machined (drilled, milled, turned, ground, etc.).
• It is not necessary to use cooling or lubricating fluids.
• Use sharp carbide tools (carbide tools recommended)
• Use high spindle speed and slow feed rate (e.g., < 30”/min)
• Make pilot holes when drilling large bores.
• Use proper measures to evacuate dust and remove chips.
DETAIL W/ 1 MM WALL THICKNESS
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Example: CNC Groove Machining
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Waterjet Cutting
1” THICK FLUXTROL 100 LOGO CUT WITH WATERJET TECHNOLOGY
Waterjet is very effective for cutting flat profiles
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Summary • Soft Magnetic Composites proved to be effective
materials for magnetic flux control in different induction
systems due to ability to work in 3D fields, excellent
machinability, good thermal conductivity and magnetic
permeability sufficient for majority applications
• Different Fluxtrol materials cover the whole range of
frequencies used in induction technique from 50 Hz up to
13.56 MHz
• Additional treatment of stock material or finished parts
allow to use magnetic controllers in special and
challenging environment
• More information about materials and their application
may be found on site www.fluxtrol.com
1388 Atlantic Blvd., Auburn Hills, MI, 48326 Ph. +1 248 393 2000, Fax +1 248 393 0277