The leading lamination replacement material
Fluxtrol LRM offers a highly efficient and cost-effective alternative to traditional laminations for induction coil applications. By choosing Fluxtrol LRM, manufacturers can significantly reduce construction time compared to standard lamination builds. Our material is available in near-net shapes and can be finished to precise sizes to meet your specific requirements. Furthermore, Fluxtrol LRM provides superior thermal performance, allowing induction coil copper to operate at lower temperatures versus traditional laminations, while also benefiting from our fast delivery capabilities
Note: There are many variables involved in an induction process. In order to utilize the fullest potential of our product, you must help narrow down the parameters you are operating with. Each grade of Fluxtrol material has its own distinctive properties that are beneficial to a certain range of electrical and design parameters.
Contact Fluxtrol Inc. to receive more information about which material is right for your application. To buy Fluxtrol LRM, fill out the contact form on this page and we will be in touch with you shortly. You can also fill out our SMC order form to directly request pricing information on Fluxtrol LRM. Click the button below to access our SMC order form.
Where Fluxtrol LRM is used
Fluxtrol LRM is engineered for a wide range of critical induction heating applications, including axle bar, crankshaft, stem, spindle, bearing, seam anneal, and specialty melting coils. By replacing traditional laminations with Fluxtrol LRM, you can achieve enhanced magnetic flux concentration, mitigate overheating in 3D magnetic fields, and reduce copper operating temperatures. This material provides superior design flexibility and better control over heat patterns compared to standard lamination builds.
Rusted laminations beginning to separate at the ends of the stack on a crankshaft coil
Key benefits of Fluxtrol LRM
Improving Efficiency and Extending Coil Life:
- Extended Component Lifespan: Users experience improved coil lifetime with Fluxtrol LRM versus laminations due to reduced copper thermal ratcheting and the elimination of rust and corrosion issues.
- Enhanced Thermal Management: No overheating in the presence of 3D magnetic fields.
- Greater Inductor Efficiency: Fluxtrol LRM covers more of the inductor for greater efficiency.
- Advanced Heat Pattern Control: Fluxtrol LRM can be positioned without keepers for enhanced heat pattern control.
- Lower Operating Temperatures: Copper operates at lower temperatures with Fluxtrol LRM versus laminations.
- Optimized Manufacturing: Less construction time versus laminations, with fast delivery and availability in near-net shapes and finished to size.
Application methods
- Thermally conductive two part epoxy is recommended.
In addition, the following mechanical fasteners may be employed.
- Secured by copper tabs
- Brass studs with washers and nuts
- Drawn together with flexible bands
- Trapped in place with non-conductive materials
Fluxtrol LRM properties
| Properties | Units | Fluxtrol LRM |
|---|---|---|
| Density ± 2% | g/cm3 | 6.6 |
| Operating Frequency Range | kHz | .05-30 |
| Initial Permeability | 63 | |
| Maximum Permeability | 120 | |
| Saturation Flux Density | Tesla | 1.6 |
| Temperature Resistance | Centigrade | 250 Long Term 300 Short term |
| Resistivity | k0hmcm | 0.5 |
| Thermal Conductivity | W / cm C | 0.2 |
Fluxtrol LRM Graphs
Ideal for low and medium frequency applications (.05 - 30kHz), Fluxtrol LRM has the highest magnetic permeability in the Fluxtrol family of soft magnetic composite materials.Our LRM product has excellent mechanical strength, thermal conductivity, and is easily machinable
Fluxtrol LRM Case Study - Extending Coil Life in Automotive Drive System Case Hardening
The Problem: The customer was struggling with an unsatisfactory coil life of only 150,000 cycles for their single-shot induction coils. This frequent failure was caused by the corrosion and overheating of the original laminations used as flux concentrators.
Application Success Report: Automotive Drive System Shaft
- Application Area: Case hardening of a shaft with multiple diameters in a static position.
- Original Setup: Used laminations as the concentrator type.
- The Problem: Short coil life (150,000 cycles) due specifically to corrosion and overheating of the laminations.
- The Result: After replacing laminations with Fluxtrol LRM, coil life more than doubled to over 300,000 cycles, with the coil still in operation.
Application Equipment Technical Specifications
- Coil Design: Single shot coil, CNC machined from solid.
- Power in Use: 480kW (Actual).
- Frequency in Use: 9 kHz (Actual).
- Heating Time: 5.1 seconds.
- Quenching Time: 8 seconds.
- Total Cycle Time: 15 seconds.
Fluxtrol LRM Results
Fluxtrol was tasked with improving the coil’s operational life on the condition that no changes would be made to the coil design or operating settings, other than a direct replacement of the laminations with Fluxtrol LRM material. After the laminations were removed and the Fluxtrol LRM was installed, the coil was returned to the production environment. The coil life has since more than doubled, exceeding 300,000 cycles, with the coil still in operation. Because no other setup changes were required, the customer is now actively looking for additional applications where they can replace laminations with Fluxtrol LRM materials to extend their production uptime.
Fluxtrol LRM Frequently Asked Questions
Is Fluxtrol LRM a cost-effective alternative to traditional laminations?
Yes, Fluxtrol LRM is aggressively priced to replace laminations, offering a cost-effective solution with the added benefits of fast delivery and reduced construction time.
Can I use Fluxtrol LRM on the same coils as other Fluxtrol materials?
Yes. Fluxtrol LRM is designed for many common coil types, including axle bar, crankshaft, stem, spindle and bearing, seam anneal, and specialty melting coils.
Will Fluxtrol LRM fix the corrosion/rusting issues I have with my current laminations?
Yes, replacing traditional laminations with Fluxtrol LRM helps eliminate rust and corrosion issues often caused by the degradation of metallic laminations.
Does installing Fluxtrol LRM require changing my current coil setup?
In many cases, no; Fluxtrol LRM can be used as a direct replacement for laminations without requiring changes to the coil design or operating settings.
How does Fluxtrol LRM improve coil lifetime compared to laminations?
Fluxtrol LRM extends coil life by reducing copper thermal ratcheting, eliminating corrosion, and preventing overheating in the presence of 3D magnetic fields.
Fluxtrol LRM Stock Sizes
| Size in Inches |
|---|
| 1.00 x 1.00 x 2.00 3/8 Channel C-Shape |
| 1.00 x 1.38 x 2.00 |
| 5/8 Channel C-Shape |
| 1.36 x 1.76 x 2.00 3/4 Channel C-Shape |
Compare Fluxtrol SMC grades
| Grade | Type | Standout properties |
|---|---|---|
| Fluxtrol A | Machinable | Highest maximum permeability and lowest magnetic losses at low to intermediate frequencies (favorable direction); good strength and thermal conductivity; readily machinable. High magnetic and thermal anisotropy. |
| Fluxtrol 100 | Machinable | Highest thermal conductivity, saturation flux density and flexural strength of the family; magnetic properties similar to Fluxtrol A with much less anisotropy; good machinability with sharp tools and high spindle speeds. |
| Fluxtrol 50 | Machinable | Excellent performance over a wide range of frequencies; good mechanical strength, machinability and thermal conductivity. |
| Fluxtrol 25 | Machinable | Good performance over a wide range of frequencies; best elasticity of the family; excellent machinability; reasonable thermal conductivity. |
| Ferrotron 559H | Machinable | Highest dielectric strength and lowest losses at high frequencies; nearly constant permeability across flux densities and frequencies; regarded by many as the most machinable grade. |
| Ferrotron 559H Original | Machinable | Similar to Ferrotron 559H with nearly constant permeability over a wide range of flux densities and excellent machinability. |
| Alpha-form MF / LF | Formable | Magnetic particles in a thermal-curing epoxy binder; molded onto the coil and oven-cured for quick, efficient installation on coils with low tolerances. |
| Fluxtrol LRM | Laminate replacement | Direct replacement for laminations; near-net shapes, lower coil-copper temperatures and shorter build time than lamination stacks. |
Properties are qualitative. Grade selection depends on frequency, coil geometry, cooling and process: ask an engineer.