Ferrotron® and Fluxtrol®
Ferrotron® and Fluxtrol® are so-called magneto-dielectric materials (MDM). They have both ferromagnetic and dielectric properties and are therefore ideal for concentrating or shielding high-frequency (1 KHZ - 5 MHz) electromagnetic fields.
Ferrotron® and Fluxtrol® consist of soft iron particles that are evenly embedded in a high-performance thermoplastic.
The soft iron-plastic compound is processed into solid semi-finished products using the press-sintering process. Various shapes and dimensions are available for machining. Components with a simple geometry can also be pressed directly into shape if sufficient quantities are available.
The magnetic and electrical properties can be specifically adjusted by the proportion, shape and distribution of the soft iron particles in the plastic. We can therefore offer Ferrotron® and Fluxtrol® grades with a magnetisation of up to 1.6 Tesla and a magnetic permeability of max. 120 µr.
The plastic used is a high-temperature polymer that can withstand temperatures of 250 to 300 °C over the long term. At the same time, the plastic gives the magneto-dielectric materials excellent processing properties so that they can be easily moulded using the usual cutting processes.
How Ferrotron® and Fluxtrol® work
Every electric field is influenced by its environment. Every conductive object that is introduced into an electric field changes it due to charge separation.
In alternating electric fields in which a current flows, an alternating magnetic field is created at the same time. These electromagnetic fields spread evenly around the current conductor. The propagation can be prevented or directed by introducing a ferromagnetic material into the field.
Ferrotron® and Fluxtrol® are ferromagnetic materials which, depending on the type, offer different levels of permeability for electromagnetic fields of different frequencies and thus permit concentration or shielding.
Due to these properties, Ferrotron® and Fluxtrol® are used, for example, to shield high-frequency electromagnetic fields in antenna technology or to align the magnetic field in the Induction heating used.
Advantages of Ferrotron® and Fluxtrol®
Magnetic field concentrators made of Ferrotron® and Fluxtrol® are also convincing in induction heating compared to conventional concentrators made of soft iron sheets (also transformer sheets or laminates) or ferrites.
Magnetic field concentrators made of Ferrotron® and Fluxtrol® offer the following advantages:
- Can be used in all frequency ranges
- Relatively high magnetisation
- no measurable Curie point
- Good effect even in 3D magnetic fields and on ring coils
- Excellent machinability (good machinability)
- Relatively high impact strength
- Insensitive to thermal shocks
- Wide range of dimensions available
Compared to soft iron sheets in particular, the effort required to adapt the concentrators to the inductor geometry when using Ferrotron® and Fluxtrol® is many times lower and the achievable precision is significantly higher.
However, the use of Ferrotron® and Fluxtrol® also has advantages in terms of energy consumption. The table below shows measured values from a test in which the same inductors were analysed once without and once with magnetic field concentrators made of Ferrotron® and Fluxtrol®.
| Without magnetic field concentrator | with Ferrotron or Fluxtrol concentrator | |
| Current in the coil (A) | 10.100 | 4.100 |
| Current voltage in the coil (V) | 42 | 33 |
| Power (kW) | 130 | 67 |
Customer trials have confirmed energy savings of 30% and more! A short YouTube video about the comparison of inductors with and without concentrators made of Ferrotron® and Fluxtrol® can be seen in the next list item!
Properties of Ferrotron®, Fluxtrol® and Alphaform®
Ferrotron® and Fluxtrol® consist of soft iron particles that are evenly embedded in a high-performance thermoplastic. The properties of the materials can be specifically influenced by the proportion, shape and distribution of the soft iron particles in the plastic.
We offer different types for different frequency ranges:
- Fluxtrol® A - for the low frequency range up to 30 kHz
- Fluxtrol® 100 - for the low frequency range up to 3 kHz
- Fluxtrol® 50 - for the medium frequency range up to 500 kHz
- Ferrotron® 559 - for the high frequency range up to 1 MHz
- Alphaform® LF - Ferromagnetic paste for applications up to 50 kHz
- Alphaform® MF - Ferromagnetic paste for applications up to 450 kHz
In addition, some special types for extremely high or very low frequency ranges are available on request.
Frequency ranges of Ferrotron® and Fluxtrol®
The various Ferrotron® and Fluxtrol® types have been developed for use in different frequency ranges:
- Fluxtrol® A - Low frequency up to 30 kHz
- Fluxtrol® 50 - Medium frequency up to 500 kHz
- Ferrotron® 559 - High frequency up to 1 MHz
Of course, the materials can also be used according to their magnetic properties or combined with each other in order to achieve a special alignment of the magnetic field.
Use of Ferrotron® and Fluxtrol® in induction heating
With the Induction heating an alternating current conductor (inductor) generates an alternating electromagnetic field. If an electrically conductive workpiece is placed in the field, the alternating magnetisation induces eddy currents in the workpiece, which lead to self-heating. This principle is mainly utilised to heat workpieces without contact, e.g. for hardening, soldering or preheating components.
Ferrotron® and Fluxtrol® can be used to manipulate the electromagnetic field so that it acts in a specific direction. This allows the following results to be achieved:
- Optimisation of the heating pattern
- Increased power of the inductor
- More efficient power utilisation
- Targeted influencing of the magnetic field
- Improved repeatability
- Protection against uncontrolled heating
YouTube video about the use of Ferrotron or Fluxtrol in induction heating
Principle of induction heating
A high-frequency alternating electromagnetic field is used to generate eddy currents in the electrically conductive workpiece to be processed. These eddy currents lead to self-heating of the workpiece.
