Improving induction tube welding system performance using soft magnetic composites

Abstract

Purpose

This paper aims to demonstrate the benefits of using different impeder materials for induction tube welding systems.

Design/methodology/approach

To show the difference in using various impeder materials, a new approach was taken to model tube welding systems in two and three dimensions. Three-dimensional (3-D) electromagnetic models were used to determine the current distribution along the weld vee as well as the permeability of the tube along the length of the welding system. Two-dimensional (2-D) coupled electromagnetic plus thermal models with rotational movement were used to determine the temperature distribution in the heat-affected zone.

Findings

Simulation results suggest upwards of 25 per cent system power savings when using a soft magnetic composite (SMC) impeder rather than the traditional ferrites.

Research limitations/implications

There is currently a lack of experimental data to validate the models, but future work will include comparison of models to real-world trials.

Practical implications

When dealing with tube welding systems, there are possibilities to improve process efficiency or increase production quality and output by improving the impeder material.

Originality/value

While simulations of tube welding systems have been done previously, studies on improving impeder materials are rarely carried out. This paper brings to light possible improvements to be made to induction tube welding systems.

Citation

Muyskens, S.M., Eddir, T.I. and Goldstein, R.C. (2020), "Improving induction tube welding system performance using soft magnetic composites", COMPEL - The international journal for computation and mathematics in electrical and electronic engineering, Vol. 39 No. 1, pp. 185-191. https://doi.org/10.1108/COMPEL-06-2019-0232