What is the best way to attach Fluxtrol to a coil?

A thin layer of epoxy is recommended for most applications, with additional mechanical methods for higher-power applications. Mechanical attachment combined with a thermally conductive adhesive or paste is the best method. For heavily loaded coils the adhesive matters, since it carries heat from the concentrator to the water-cooled copper.

How should I machine Fluxtrol materials?

All Fluxtrol materials can be turned, ground, milled, saw-cut and drilled, and water jet cutting works well for 2D parts from plate. Carbide tools work best and high speed steel also works well. Establish optimal machining regimes on samples before producing multiple parts.

Why do concentrators fail?

The main causes are mechanical damage, overheating and electrical break. Poor cooling is the most common cause of overheating, and others include improper material selection, unfavorable coil design and improper assembly. Protecting the concentrator from impacts, electrical break and overheating extends its life.

Are Fluxtrol materials safe to machine?

Machining chips are not hazardous, and solid pieces do not support fire. Accumulated dust or debris can support a smoldering fire, and friction is the primary source of ignition. Use general metalworking precautions, clean collection trays and never use a vacuum-type dust collector. See the machining safety page for full precautions.

Installing SMCs on an Induction Coil

From raw plate to a working, long-lived flux controller.

Installing Fluxtrol soft magnetic composites on an induction coil follows five stages: machine the controller to shape, assemble it on the coil with thermally conductive adhesive and mechanical fixing, protect it from damage and the environment, maintain it in service, and follow machining safety and fire precautions.

Getting the full benefit of a Fluxtrol soft magnetic composite (SMC) depends as much on how it is installed as on which grade you choose. Magnetic, electrical, thermal and mechanical aspects all affect the selection of the material, its treatment and how it is applied to the coil. The pages in this section follow the order of a typical job.

1. Machining

All Fluxtrol products have excellent machinability, which lets users make controllers of any geometry, including parts with wall thickness under one millimeter. The materials can be turned, milled, drilled, ground and saw-cut, and water jet works for flat parts. Orientation matters in critical cases because the pressed grades are anisotropic. See Machining Soft Magnetic Composites , which includes video demonstrations.

2. Assembly

Adhesive bonding is the most common attachment method, and the goal matters: holding the controller in place is different from cooling it through the coil copper. Epoxy is most common, mechanical fixing is the most accurate and reliable, and brass or stainless inserts and fasteners suit bolted joints. See Assembling SMCs on an Induction Coil .

3. Protection

With additional protection such as etching, coating and impregnation, controllers can work in demanding environments. Protection also covers mechanical damage, overheating, environmental impact and electrical discharge. See Protecting SMC Flux Controllers .

4. Maintenance

In many applications Fluxtrol concentrators outlast the copper. Reliable performance still depends on guarding against mechanical damage, overheating and electrical break. See Maintaining Induction Coils with SMCs .

5. Safety

Chips from machining are not hazardous, but accumulated dust can smolder if friction sparks land in it. See Machining Safety & Fire Precautions before you start cutting.

Need help with an installation?

Fluxtrol provides technical support for existing and potential customers. Contact the team for advice, or order SMC materials .

Installing SMCs on an Induction Coil

1. Machining

2. Assembly

3. Protection

4. Maintenance

5. Safety

Need help with an installation?

Explore

Machining Soft Magnetic Composites

Maintaining Induction Coils with SMCs

Assembling SMCs on an Induction Coil

Machining Safety & Fire Precautions

Protecting SMC Flux Controllers

Optimizing an induction process?