A Novel Topology for a High-Frequency Pulsed Arc-Welding Power Supply

A Novel Topology for a High-Frequency Pulsed Arc-Welding Power Supply | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article A Novel Topology for a High-Frequency Pulsed Arc-Welding Power Supply Zhenmin Wang, Yuhai Wang, Zhiyu He, zuguang Zhu, Peng Chi, Qin Zhang This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8587074/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 4 You are reading this latest preprint version Abstract Pulsed current can constrict the welding arc and enhance arc force, thereby promoting improved stirring within the molten pool. This effect has been widely studied and applied in the welding of metallic materials. In this paper, a high-frequency pulsed DC power supply is proposed for pulsed arc welding applications. The system comprises a constant-current source, a high-frequency pulse modulation circuit, and an energy recovery circuit. The output current amplitude (0 ~ 140 A) is regulated by the constant-current source, while the pulse frequency (20 ~ 40 kHz) and duty cycle (0 ~ 100%) are independently controlled via the pulse switching circuit. To suppress voltage spikes and recover energy from the output cable, an active clamping technique is applied to the switching devices in the modulation stage. This configuration enables rapid rise and fall times of the pulsed current, with controllable current slew rates. Furthermore, by optimizing the pulse control strategy, zero-voltage switching (ZVS) is achieved for the main switches, improving overall efficiency and reducing switching losses. The operating principles of the proposed topology are analyzed in detail, and key design parameters are calculated and presented. To verify the proposed topology, a laboratory prototype was built and tested, featuring a peak pulse current of 140 A and a maximum pulse repetition frequency of 40 kHz. DC pulse Arc welding application Active clamp High frequency Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 14 Jan, 2026 Reviewers invited by journal 14 Jan, 2026 Editor assigned by journal 14 Jan, 2026 First submitted to journal 12 Jan, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8587074","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":574745667,"identity":"4edbf0cf-59c4-4ae9-9ff5-f3683b957bd8","order_by":0,"name":"Zhenmin Wang","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Zhenmin","middleName":"","lastName":"Wang","suffix":""},{"id":574745668,"identity":"42324ee3-5b86-4e0f-aac3-37f30978b997","order_by":1,"name":"Yuhai 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This effect has been widely studied and applied in the welding of metallic materials. In this paper, a high-frequency pulsed DC power supply is proposed for pulsed arc welding applications. The system comprises a constant-current source, a high-frequency pulse modulation circuit, and an energy recovery circuit. The output current amplitude (0\u0026thinsp;~\u0026thinsp;140 A) is regulated by the constant-current source, while the pulse frequency (20\u0026thinsp;~\u0026thinsp;40 kHz) and duty cycle (0\u0026thinsp;~\u0026thinsp;100%) are independently controlled via the pulse switching circuit. To suppress voltage spikes and recover energy from the output cable, an active clamping technique is applied to the switching devices in the modulation stage. This configuration enables rapid rise and fall times of the pulsed current, with controllable current slew rates. Furthermore, by optimizing the pulse control strategy, zero-voltage switching (ZVS) is achieved for the main switches, improving overall efficiency and reducing switching losses. The operating principles of the proposed topology are analyzed in detail, and key design parameters are calculated and presented. 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