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ASM 2013 Fluxtrol Paper - Innovations in Soft MagneticComposites and their Applications in Induction Systemsby Fluxtrol Inc. on Nov 06, 2013
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In induction hardening, thermal fatigue is one of the main failure modes of induction heating coils. There have been
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ASM 2013 Fluxtrol Paper - Innovations in Soft Magnetic Composites and their Applications inInduction SystemsDocument Transcript
1. Innovations in Soft Magnetic Composites and their Applications in
Induction Systems R. Ruffini, N. Vyshinskaya, V. Nemkov, R. Goldstein, C.J.
Yakey Fluxtrol Inc., Auburn Hills, MI USA [email protected], 248-393-2000,
www.fluxtrol.com Abstract New soft magnetic composites have been added to
the current family of materials produced by Fluxtrol Inc. which allows users to
increase their range of magnetic flux controller applications and improve their
overall inductor performance. A new material (Fluxtrol 100) is a substitution for
a current well known material (Fluxtrol A). This new material has better
mechanical properties, machinability and low anisotropy. The formable
materials of Alphaform are effective on I.D. induction coils and various small
coils of complex geometries. These materials may be used at any frequency, up
to several megahertz. Along with the description of new materials, this
presentation contains information about recent improvements in application of
Fluxtrol materials including preparation, forming and gluing. One of new
methods is impregnation of magnetic concentrators. This advanced
technology consists in vacuum treatment of magnetic controllers or whole
induction coils with subsequent placing them into a bath of a special resin.
Resin penetrates into the material pores and gaps between the concentrators
and copper turns and polymerizes inside of them. This treatment increases
mechanical strength of the material and total assembly and improved corrosion
resistance. Induction coils for axle and crankshaft hardening as well as small
ID coils are selected for illustration. Introduction Magnetic Controllers on
Heat Treating Inductors Modification of magnetic field distribution and
control of its intensity on the surface of the parts to be heated may be
accomplished by different methods: by variation of the coil turn shape and
positioning, by insertion of non-magnetic shields and magnetic templates that
may be called magnetic controllers. Non-magnetic shields, typically made in
the form of copper rings or massive copper blocks, are often called “flux
robber rings” [1]. Their use leads to reduction of the coil power factor and
efficiency and they are not considered in this paper. Magnetic flux controllers
are made of soft magnetic materials: steel laminations, ferrites and magnetic
composites. Magnetic controllers can concentrate field in required areas (field
concentration), change field distribution, shield certain areas from unintended
heating and strongly reduce the magnetic field outside the treatment area. The
team of Fluxtrol Inc. has developed the basics of magnetic flux control
including the theory, methods of simulation and design, application technique
guidelines. A course that contains these topics as well as the basics of
induction heating may be found on the company website under the tab
Training [2]. A role of magnetic flux control and methods of computer design
of induction coils with magnetic controllers are presented also in multiple
papers, e.g. in [3-5]. The use of magnetic controllers on heat treating induction
coils can provide accurate control heat pattern, improvement of the coil
efficiency and power factor, better utilization of power transferred to the part
in local heating processes. It can also result in reduction of the coil current
demand thus improving performance of the whole induction system and
protect machine or the part components from unintended heating Technical
and economic effects of magnetic flux controllers are the following: better part
quality, higher production rate or energy savings, reduction of required power
of the heating equipment. The most effective design method of the induction
coil with magnetic controllers is to use computer simulation [3]. In this way
both the coil copper and concentrator may be optimized for the best
performance in a particular application. It is important to state that the
controller design, selection of material and application technique can strongly
influence performance and lifetime of heavy loaded induction coils. The goal
of this paper is to inform the induction community about the latest
improvement in development and application of magnetic controllers.
2. Materials for Magnetic Controllers on Heat Treating Inductors There are
three groups of materials that can be used for magnetic flux controllers:
laminations, ferrites and Soft Magnetic Composites (SMC), aka
MagnetoDielectrics Materials (MDM). Laminations are thin sheets
of electrical steel with thin electrical insulation on their surface. They
are working well in plane-‐parallel (2D) magnetic fields at frequencies up
to 20 kHz, sometimes even at 30 kHz. Advantages of laminations are:
very high permeability, high temperature resistance, high thermal
conductivity in the plane of sheets, low magnetic losses at low
frequencies. Lamination drawbacks are: overheating in 3D magnetic
fields, limited frequency range, difficulty in machining and installation,
resulting in high labor costs in the case of complex coil geometry.
Ferrites are glass-‐like materials made of oxides of iron, manganese, zinc
and other elements. In spite of high permeability (in weak magnetic
fields only!) and relatively low losses, they are used in rare cases of
high frequency coils of small sizes due to the following drawbacks: -
They are very hard and brittle and practically non-‐machinable -
Saturation flux density is low (up to 0.3-‐0.4 T) - Low service temperature
for majority of types due to low Curie point - Low thermal conductivity
SMCs are made from ferrous particles (iron and its alloys), covered with very
thin insulation layer, mixed with organic or inorganic binder, pressed at high
pressure (up to 720 MPa and even higher) and cured according to a special
technology. Majority of SMC used in induction industry have organic
binders, which provides good machinability. All pressed materials have certain
anisotropy (up to 1.5-2 times in permeability depending upon structure) but all
of them work well in 3D fields. High frequency materials have low anisotropy.
Possibility to work in 3D fields and good machinability are highly valued by
the coil manufacturers. Different types of SMC cover the whole range of
frequencies used in induction heating (50 Hz – 13.56 MHz). Losses at low
frequency are comparable to laminations and at high frequencies – to ferrites.
Temperature resistance is lower than for laminations but usually sufficient for
induction applications. High thermal conductivity (up to 0.23 W/cmK, i.e. 35%
higher than solid stainless steel material) and possibility of effective thermal
management using external or internal cooling can keep controllers safe in
heavy loaded cases. The main drawbacks of SMC are limited dimensions (up
to 220 mm long plates at present time and higher price of material. However
with account for labour cost and possible improvement in coil life time, use of
SMC in many cases occurs cheaper that laminations. It is especially correct
when using net-shape manufactured or machined controllers, fig.1. Technical
and economic analyses show that in some cases a combination of different
materials give excellent results. For example, laminations may be used for the
regular part of controllers and SMC for areas with complex shape and 3D field,
such as the end zones of seam annealing coils. Figure 1: SMC blocks painted
for identification (left) and different machined magnetic controllers (right)
3. SMC is a class of materials that was significantly improved during the last
decade. There are newer materials with improved properties such as Fluxtrol
100, Fluxtrol LF designed for low frequency applications (shielding of melting
furnaces, low frequency heat treating, etc.) and formable materials of
Alphaform type, which can be applied to inductors of irregular shape
manufactured with low tolerance. Several studies have been performed in
order to improve technique for application of magnetic controllers to the coils
and to develop corresponding guidelines for users. New SMC Materials
Properties of new materials are presented in Table 1 in comparison with
traditional material Fluxtrol A. Table 1: Properties of Fluxtrol 100, Fluxtrol LF
and Alphaform materials in comparison with Fluxtrol A Fluxtrol 100 Fluxtrol 100
is a new material with different insulation and binder complex than traditional
Fluxtrol materials (Fluxtrol A, 50 and Ferrotron 559 and 119). It is designed for
use in a wide range of frequencies up to 50 kHz instead of Fluxtrol A. Material
has lower anisotropy than Fluxtrol A and better mechanical properties, which
allows the users to machine parts with sharp corners and thin walls. Magnetic
properties of Fluxtrol 100 and A are very similar in favorable direction
perpendicular to direction of pressing, fig.2. Permeability of Fluxtrol 100 in
direction of pressing is much higher than of Fluxtrol A and it does not require
the user to care about material orientation when designing the controllers.
Thermal conductivity of Fluxtrol 100 is also higher and it allows us reduce the
rated temperature of material to 200 C. However material can work for a long
time at temperature 250 C with the same magnetic properties and reduced
electric resistivity. Figure 2: Magnetic permeabilities of Fluxtrol A and 100 in
two directions Alphaform materials
4. These materials are manufactured from magnetic particles of different
dimensions for “lower” (LF), middle (MF) and high frequencies (HF) mixed
with a special epoxy compound. Alphaform material is supplied in tins, which
is advised to keep refrigerated for longer life time, fig. 3, left. Materials may be
manually formed/shaped when warm. After that the coil must be heated for
curing. During heating the material passes through the transient stage when it
becomes relatively thin to flow out and special coating or wrapping is
necessary. Figure 3: Tins with Alphaform materials (left) and ID induction coil
with magnetic core (right) Alphaform materials may be effectively used on ID
induction coils and wrapped tubing coils of complex or irregular geometries
due to its flexibility during application. Material sticks to copper tubing
resulting in good mechanical integrity and very good thermal contact even for
non-machined coils with significant tolerances, fig.3, right. Due to the ease of
installation (and removal when needed) this SMC are also great for lab and
development projects where immediate results are needed. SMC Controllers on
Crankshaft Hardening Coils Over the last 5 years a big progress has been
made in use of Soft Magnetic Composites in the Elotherm (rotational) style
and clamshell (non-rotational) style crankshaft induction hardening coils. In
rotational style inductors laminations have been the norm for decades, but
SMC have proven to be more cost effective in coil assembly techniques and
overall coil performance, including inductor lifetime. The ease of installation
and modification make for easier adjustments at setup. More complex coil
designs can be achieved to deal with more challenging aspects of crankshaft
hardening such as fillets and undercuts due to the flexibility/machinability of
SMC materials, fig.4. Figure 4: Hardness pattern (left) and induction coil with
Fluxtrol 100 concentrators, right In clamshell or non-rotational inductors the
application of SMC controllers provides excellent heat pattern control in
journal circumference and width while reducing the required amount of power
needed to achieve pattern specifications. Along with improved heat pattern
uniformity we now have industry feedback confirming increased coil life due
to the application of side shields in these types of inductors. As these types
of applications grow, more and more data is being gathered for analysis and
comparisons to older styles of crankshaft magnetic controllers.
5. Recommended Application Techniques for Soft Magnetic Composites
Fluxtrol Inc. is constantly pursuing the best ways to not only adhere our
material to inductors, but to make it easier for our customers to access this
technology and apply it themselves with ease and confidence. This way
insuring our material is performing at its peak, is structurally sound and being
cooled to the best of its applications ability. All of which leads to the best
performing induction systems available. Many factors come into play when
attaching Fluxtrol material to an inductor. First and foremost is the use of the
proper grade of Fluxtrol for your application Conclusions Fluxtrol, Inc.
continues to improve existing and introduce new composite materials to meet
industry demands. Magnetic flux controllers can improve heat pattern, prevent
unintended heating of the part or hardening machine, improve induction coil
parameters and performance of the whole induction installation. As a result,
proper application of magnetic flux controllers can strongly improve heat
pattern control, increase production rates, save energy and cut manufacturing
costs. Soft Magnetic Composites manufactured by Fluxtrol Inc. are the primary
choice for magnetic controllers. They cover the whole range of frequencies
used for induction heat treating (from line frequency up to several megahertz),
may be easily machined to any desirable shape and used as constructive
elements of the coil. Magnetic permeability of these SMC reaches 120, which
is sufficient for almost all induction heating applications. The most effective
way to design induction coils with magnetic controllers is to use computer
simulation, which can predict the coil performance prior to its manufacturing.
6. References [1] Nemkov, V., “Magnetic Flux Control in Induction
Installations,” Proc. of Int. Symposium HES-13 “Heating by Electromagnetic
Sources”, Padua, Italy, May 2013 [2] Website www.fluxtrol.com [3] Goldstein,
R. et al., “Virtual Prototyping of Induction Heat Treating”, Proc. of the 25th
Conf. ASM Heat Treating Society, Indianapolis, September 2009 [4] Nemkov,
V., Goldstein, R., “Design Principles for Induction Heating and Hardening”, in
Handbook of Metallurgical Process Design. Chapter 15. Marcel Dekker; New
York, NY-USA. 2004; pp. 591–640 [5] Nemkov V., Goldstein R., Ruffini R.,
“Optimal Design of Induction Coils with Magnetic Flux Controllers,” ” Proc. of
Int. Symposium HES-07 “Heating by Electromagnetic Sources”, Padua, Italy,
2007 [6] Ruffini, R., Nemkov, V., Vyshinskaya, N., “New Magnetodielectric
Materials for Magnetic Flux Control. ”Proc. of Int. Symposium HES-04,
“Heating by Electromagnetic Sources”, Padua, Italy, June 2004 [7] Nemkov, V.,
Goldstein, R., “Optimal Design of Internal Induction Coils,” Proc. of Int.
Symposium HES-04 “Heating by Electromagnetic Sources”, Padua, Italy, 2004
[8] Myers, C. et al., “Optimizing Performance of Crankshaft Hardening
Inductors,” Industrial Heating, December, 2006
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