Physical Simulation and Computational Modelling for Validation of Soft Magnetic Composite Impeder Performance

Induction tube welding is used for the continuous production of metallic tubes. These systems often utilize an internal magnetic flux controller (impeder) to improve process efficiency. Significant energy savings and increased productivity have been demonstrated both theoretically and practically when switching from the traditional ferrite impeder core, to one made of a soft magnetic composite (SMC) with high saturation flux density. In order to use SMCs in these systems it is important to balance the greater heat generated in these materials at higher fields with the cooling water available.

In a previous study, a test stand was devised for physical simulation of SMC impeder performance for use in induction tube welding systems. Design envelopes were created outlining the conditions in which impeder cores made of SMCs could survive in induction tube welding systems. The goal of this study is to build upon those initial findings through extended physical simulation using an improved test stand, as well as the implementation of CFD modelling to expand the experimentally developed operational envelopes to the theoretical limits of the material. This will expand these operational ranges to cover a wider range of process frequencies and magnetic core loading in induction tube welding systems and provide a better idea of the applications in which SMC impeders may be effectively used.