Publication Date


Document Type


Committee Members

Marian Kazimierczuk (Advisor), Marian Kazimierczuk (Committee Member), Saiyu Ren (Committee Member), Ronald Riechers (Committee Member)

Degree Name

Master of Science in Engineering (MSEgr)


Arc welding machines are typically large, heavy devices that transform an alternating current (AC) input into a low-voltage, direct current (DC) output. Traditionally these high power devices have required steel and copper transformers that account for their bulky size and weight. While the cost of raw materials in electromagnetic components has been increasing the cost of high-power silicon devices has been decreasing. This disparity creates an opportunity for a cost-effective DC-DC switching welder in the consumer market. While DC-DC power electronics are not new to the welding industry, this study, under the commission of a welding equipment manufacturer, aims to develop and prototype a design specifically for an affordable and portable battery-powered welding machine. By eliminating the need for electromagnetic components for isolation and voltage regulation, and focusing on a DC-DC battery-powered device, a unique opportunity exists to create a high-feature product with a minimalist design. The design is implemented with a high-current voltage chopping circuit as well as an assortment of feedback, control, and safety circuitry necessary to complete the machine. By combining simulation, prototype validation and real-world cost limitations, this project outlines the development of a new product for the welding equipment market.

Page Count


Department or Program

Department of Electrical Engineering

Year Degree Awarded