Case Studies

Application: Case Harden Wheel Hub with Single Bearing Race
Original Concentrator: Silicon Steel Lamination
Problem / Failure Mode: Short Coil Life / Copper Failure of 2 Half Turns Copper
Power Supply: 150 kW ( 100 kW in use), 10–25 kHz (15 kHz in Actual Use)

Problem / Solution: - Customer experiencing life of 8,000 to 13,000 cycles

• Laminations replaced with Fluxtrol A, no other changes
• Lifetime increased to 15,000 to 20,000 cycles
• Optimized coil design via computer simulation
• New coil design utilizes Fluxtrol 50 material
• Tests meet spec and coil returned to production

Fluxtrol Advantage: Coil Life Extended to > 150,000 Cycles!

Application: IH Aluminum Brazing of Heat Exchanger
Original Concentrator: Ferrotron 559H
Problem / Failure Mode: Cold Joints, Leaking Joints, Localized Overheating
Power Supply: 60 kW (30 kW in use), 10–25 kHz, (12–15 kHz in use)

Problem / Solution: - Customer experiencing long cycle times & poor quality

• Fluxtrol A chosen as concentrator
• Condition simulated using computer simulation
• Optimized coil design via computer simulation
• New coil design utilizing Fluxtrol A built and tested
• Tests meet spec and new coil put into production

Fluxtrol Advantage: No Quality Issues & 30% Cycle Time Reduction!

Application: Automotive Camshaft / Static Hardening Coil
Original Concentrator: None
Problem / Failure Mode: Unsatisfactory Cycle Times & Poor Heat Pattern Control
Power Supply: 100 kW (70 kW in use), 10 kHz, (8 kHz in use)

Problem / Solution: - Customer not satisfied with cycle times and back tempering of adjacent lobe

• Application evaluated and Fluxtrol A selected
• No other changes were made other than adding Fluxtrol A
• Tests meet spec and coil returned to production

Fluxtrol Advantage: Cycle Time Reduced 26%, Power Reduced 30% and No Back Tempering of Adjacent Lobes!

Application: Case Harden S-Cam and Shaft
Original Concentrator: None
Problem / Failure Mode: Extended Cycle Times / Loss of Pattern Control
Power Supply: 150 kW (135 kW in use), 3–10 kHz (7 kHz in use)

Problem / Solution: - Customer not satisfied with cycle times

• Fluxtrol given opportunity to replace laminations
• Coil and application reviewed for pattern and time
• Optimized coil design via computer simulation
• New coil design utilizes Fluxtrol A material
• Tests meet spec and coil returned to production

Fluxtrol Advantage: Cycle Time Reduced 46% with Pattern Improvement!

Application: Case Harden Shaft by Rotating in Static Position
Original Concentrator: Silicon Steel Laminations
Problem / Failure Mode: Short Coil Life / Corrosion & Overheating of Laminations
Power Supply: 600 kW (450 kW in use), 3–10 kHz (9 kHz in Actual Use)

Problem / Solution: - Customer not satisfied with life of 150,000 cycles

• Fluxtrol given opportunity to replace laminations
• Application evaluated and Fluxtrol 50 chosen
• No other changes were made other than Fluxtrol 50
• Laminations removed and replaced with Fluxtrol 50
• Tests meet spec and coil returned to production

Fluxtrol Advantage: Coil Life Extended to > 300,000 Cycles!

Application: IH Fastener Heat Treating / Channel Coil
Original Concentrator: None
Problem / Failure Mode: Insufficient Production Rate
Power Supply: 25 kW (15 kW in use), 150 – 400 kHz (200 kHz in use)

Problem / Solution: - Customer not satisfied with cycle times

• Power supply at current limit
• Customer need to increase production w/limited expense
• Application evaluated and Fluxtrol 50 selected
• No other changes were made other than adding Fluxtrol 50
• Tests meet spec and coil returned to production

Fluxtrol Advantage: Production Rate Increased 100%!

Application: Geared Tractor Hub / Simple O.D. Coil with Integral Quench
Original Concentrator: None
Problem / Failure Mode: Long cycle times and poor heat pattern control
Power Supply: 50 kW (22 kW in use), 10 kHz

Problem / Solution: - Customer not satisfied with cycle time

• Customer experiencing high scrap rates
• Application evaluated and Fluxtrol A selected
• No other changes were made other than adding Fluxtrol A
• Fluxtrol applied per supplied guidelines
• Tests meet spec and coil returned to production

Fluxtrol Advantage: Cycle Time Reduced 42%, Positive Control of Heat Pattern!