Fluxtrol Laminate Replacement Material

Cost-effective, high-performance direct replacement for traditional laminations in induction coils with Fluxtrol LRM.

Fluxtrol LRM: 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.

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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 Using 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.

Fluxtrol LRM 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

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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.

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