Modelling and Simulation for a Versatile Controllable Power Supply Configuration Appropriate for Magnetically Impelled Arc Butt (MIAB) Welding

This article presents the design and development of a power source for industrial applications, focusing on improving energy efficiency, control, and reliability. The study is primarily focused on designing an optimized electrical power source for Magnetically Impelled Arc Butt (MIAB) welding, which is a solid-state welding process characterized by specific current requirements. MIAB welding involves variation of current in two stages of the welding sequence. The objective of this study is to propose an appropriate power supply configuration that meets the precise amperage control and also ensures machine compactness and automation of the process. Utilizing state-of-the-art simulation tools, the research explores various design parameters and configurations to achieve the desired current modulation efficiently. The inverter-based welding power source is tested for the welding of tubes of MS1018 material by implementing parametric variations to validate its workability and performance. The findings indicate that the proposed power supply configuration can enable the required control and also provide a compact power supply unit for MIAB welding, paving the way for its broader industrial adoption and implementation. This research contributes to the advancement of welding technology by providing a robust solution to the challenges associated with arc dynamics and amperage modulation in MIAB welding, ultimately leading to improved weld quality and process efficiency. The proposed power supply design demonstrates potential applications well beyond MIAB welding, offering versatility for any process requiring controlled amperage variation during its operation cycle.