Hi all ,
i am designing a 100 A stick welder , i used two switch forward converter topology and toiroid 24:8 toroid power transformer, the problem is my igbt blows after a small amount of time , and somebody tell me that the issue is in my layout , you find attached the schematic and the layout, can you please help me to find where is the problem with my layout with blows the igbt sudenly , i am using a ground plane and short traces to reduce stray inductance and a totem pole driver to reduce the igbt control loop.

 

Why are You trying to use a fancy Switching-Circuit for a Stick-Welder ?
A good-ole "Buzz-Box" AC-Welder works great,
just like they have for the last ~100 years or so,
and they're really cheap.

Unless You are an experienced Welder,
who knows exactly what they want, and why they want it,
I would advise sticking with a "Buzz-Box" until
You get really good at old-school AC-Stick-Welding.

On the other hand,
a cheap "Flux-Core" Welder from Harbor-Freight is hard to beat,
it's more versatile than a Stick-Welder, and easier to learn.
.
.
.

 

Why are You trying to use a fancy Switching-Circuit for a Stick-Welder ?
A good-ole "Buzz-Box" AC-Welder works great,
just like they have for the last ~100 years or so,
and they're really cheap.

Unless You are an experienced Welder,
who knows exactly what they want, and why they want it,
I would advise sticking with a "Buzz-Box" until
You get really good at old-school AC-Stick-Welding.

On the other hand,
a cheap "Flux-Core" Welder from Harbor-Freight is hard to beat,
it's more versatile than a Stick-Welder, and easier to learn.
.
.
.

Good idea I will check