Crankshaft inductor with concentrator 

attached with epoxy adhesive  

 

 

Scanning inductor with concentrator

attached with epoxy adhesive  

 
 

 

 

 

 
 

 

Camshaft hardening inductor with

concentrator mechanically attached 

 

 

 

Tranmission gear hardening inductor (interanl surface) 

with concentrator mechancially attached  

 

 
Safety / Machining

Our materials may be machined using various methods (drilling, milling, turning, grinding, etc.).  It is not necessary to use cooling or lubricating fluids.  General Rules:  Use sharp tools with slow feed and fast speed.  Make pilot holes when drilling large bores.  Drill material on strong support (wooden or plastic block) to avoid chipping.

Our flux concentrator products are soft magnetic composites consisting of metal powders and dielectric binders compacted a high pressures with subsequent thermal treatment. The metal powder may be a source of combustion.   

The primary source of combustion is friction.  Red hot chips or parks?may be thrown off, fall or drop into the collection tray of a lathe, inside a bandsaw or near the grinding wheel dust.  If these sparks land on accumulated machining dust or debris, they could cause a smoldering fire.  If left unattended, a fire could result.  Coolant is not suggested, in that it impedes the cutting process and is not necessary, if precautions are observed.

   Precautions to be observed are as follows:      
   

 1.

  Clean all collection (or atch? trays before machining Fluxtrol & Ferrotron concentrators, removing any remnant debris or oils.  
   

  2.

  Cut at slow speed and feed as in cutting stainless steels.  
   

 3.

  Never use vacuum cleaner type dust collectors to catch falling dust or debris.  Instead, use an approved dust collector over the machining operation.  This is best for removing all airborne particles.  
   

   4.

 

 Inspect by spreading dust and/or debris for accidental combustion during and after machining operations.  Use water and wet rags to extinguish any glowing/smoldering areas.  DO NOT INHALE SMOKE OR FUMES.

 

 

 

 

 

 Read the hazardous material section of our soft magnetic materials Material Data and Safety Sheets found in the section.

 

Our Fluxtrol materials are strong in compression, less strength in tension or bending loads.  They may be machined to any shape, drilled for coolant or mechanical attachments. Threads may be cut directly in material for fastening, but helicoils are recommended for heavy mechanical applications.    

Surface Preparation

Best Fluxtrol material perfromance may be realized when sufficient care is administered to prepare Flux Concentrator material (magnetic flux controller) and Induction Heating Coil in the area of attachment/interface as described below:

Fluxtrol Flux Concentrator - Clean all surfaces that are to be in intimate contact with Induction Heating Coil by removing any paint.  Lightly sand with edium?to edium-fine?emery paper (80-180 grit) to give adhesive a good ripping?surface.  Remove any accumulated dust by wiping with a clean dry cloth or with an organic solvent (such as acetone). 

Induction Heating Coil - Clean all surfaces that are to be in intimate contact with Fluxtrol Flux Concentrator by removing any machining fluids/oils or residual quenchant.  This may include sandblasting the copper surface and then wiping it with an organic solvent (such as acetone).  Lightly sand with edium?to edium-fine?emery paper (80-180 grit) to give epoxy adhesive a good ripping?surface.  Remove any accumulated dust by wiping with a clean dry cloth. 
     
   

 
  The above figure is provided as a surface preparation procedure concept only.  For assistance related to this technique, please contact Fluxtrol customer service department.  

 

Attachment of Fluxtrol to Induction Coil

There are two main methods for attaching Fluxtrol Flux Concentrators to the Induction Coil:

  Adhesive Bonding
 

Mechanical Attachment

For both attachment methods, flux concentrator material perfromance is advanced when it is in the best possible thermal contact with the induction coil.  This can be achieved through the use of a uniform and thin layer of a thermally conductive 搈edium?in-between the contact surfaces. 

     
     
     

Adhesive Bonding is the most common method of attaching Fluxtrol flux concentrator product to an induction heating coil.  Any epoxy adehsive used must have the following characteristics:

  • high temperature stability                              
  • electrically non-conductive               
  • high bond strength
  • good thermal conductivity
  • low moisture absorption
  • chemical resistance 

Care should be taken to clean all dirt, oils, greases and mechanically roughen the contact surfaces prior to bonding.  A thin layer of epoxy adhesive should be applied to both the Fluxtrol product and induction coil copper contact surfaces and then these two surfaces are to be brought into contact and held together with light pressure.  Wipe away the excess glue with a damp cloth and then follow the curing instructions for the respective adhesive.

For common applications (lightly loaded having larger tolerances etc.),  we suggest a gap or space in-between Induction Coil copper and Fluxtrol product of 0.008" - 0.012" (0.2 mm - 0.3 mm). and use the Dexter Hysol Product 1C Epoxi-patch Kit from Loctite Coproration.

 

For severe applications (heavily loaded having high flux density and long duty cycles), we suggest a gap or space in-between Induction Coil copper and Fluxtrol product of and recommend Durelco 4525 high temperature epoxy adhesive from Cotronics Corp. ".  A thin epoxy layer of this epoxy type 0.004" - 0.006" (0.10 mm - 0.15 mm) may be applied evenily to the induction coil & flux concentrator. 

Note: Silicone rubber is a poor thermal conductor and is recommended for use only in lightly loaded inductor coils. 

If an E-shaped concentrator is broken into two isolated C-shaped sections, no electrical insulation between the coil tubing, stud and concentrator is necessary (see below figure).  

     
   

 
  The above figure is provided as an adhesive bonding application concept only.  For assistance related to this technique, please contact Fluxtrol customer service department.  

 

     

 

   

     

 

Mechanical Attachment ois another example of how Fluxtrol flux concentrators are attached to an Induction Heating Coil.  The purpose for the mechanical fastner is to keep the flux concentrator in a secured postion (i.e., in place).  A technique may be used where a stud (i.e., screw or bolt made from brass or copper) is brazed to the induction coil coupled with a clearance hole drilled through the Fluxtrol product.  Use where possible a thermal medium that is electrically non-conductive and thermally conductive "heat sink paste" (usually silicone based), like those used for mounting transistors in power supplies.  Both the Fluxtrol product and Inductor contact surfaces should be coated with a thin and uniform layer prior to fastening.  After tightening down the nut on the stud, excess paste should be wiped away with a dry rag.   BE careful no to over-tighten the nut, as this may lead to cracking of the Fluxtrol Flux Concentrator.

   
   

 
   The above figure is provided as a mechanical fastening application concept only.  For assistance related to this technique, please contact Fluxtrol customer service department.  

 

As an alternative to mechanical fastening, mechanical assembly (please see photo below) is a viable option where induction coils are exposed to high intensity manufacturing environments, such as heavy loaded, highly automated and operate 365/24/7. 

     
     
   

 
   
友情链接:    彩票平台   VR竞速彩票代理   VR竞速彩票官方网站   6118彩票计划   百宝彩票开奖网   





qq彩票开户 ug990.com