This paper aims to demonstrate the benefits of using different impeder materials for induction tube welding systems.
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.
Simulation results suggest upwards of 25 per cent system power savings when using a soft magnetic composite (SMC) impeder rather than the traditional ferrites.
There is currently a lack of experimental data to validate the models, but future work will include comparison of models to real-world trials.
When dealing with tube welding systems, there are possibilities to improve process efficiency or increase production quality and output by improving the impeder material.
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.
