International Scientific-Technical and Production Journal
October
2010
# 10
English translation of the monthly «Avtomaticheskaya Svarka» (Automatic Welding) journal published in Russian since 1948
Founders: E.O. Paton Electric Welding Institute of the NAS of Ukraine
International Association «Welding»
Editor-in-Chief B.E.Paton
Publisher: International Association «Welding»
CONTENTS
Editorial board:
Yu. <...> Copies of individual articles may be obtained
from the Publisher.
© PWI, International Association «Welding», 2010
Lebedev V.A. Tendencies in development of mechanized
welding with controlled transfer of electrode metal (Review) ................ 37
BRIEF INFORMATION
Bondarev A.A., Tyurin Yu. <...> Adequacy of the model was evaluated by
comparing the sizes of the real and simulated weld sections. <...> K e y w o r d s : TIG and A-TIG welding, nickel alloy, penetration, mathematical model, adequacy of mathematical model
Positive results connected with an abrupt increase of
penetration depth at activating flux deposition on the
surface of metal to be welded in TIG welding (A-TIG
process ) of titanium obtained at the E.O. Paton Electric Welding Institute [1, 2] stimulated investigations
on arc column contraction in TIG welding of steels
and other materials [3—5]. <...> However, at temperature increase up to
1900 °C, surface tension reaches values characteristic
for pure metal with a maximum at critical temperature, and values of dσ/dT coefficient again become
negative, as for pure metal. <...> World’s first two-dimensional model of weld pool
convection [8], created in 1983, provided theoretical
confirmation of the postulates of [6] and showed that
Marangoni surface tension forces are predominating,
and together with the Lorentz electromagnetic forces
they are responsible for appearance of double eddy
regions. <...> Later it was established [9] that the sign of
thermal concentration dependence of surface tension
and its values determine the direction of convective
heat transfer under the arc and number of vortices. <...> Simulation of the role of electromagnetic forces in
A-TIG welding is carried on, and the nature of the
mechanism of this phenomenon still has not been de-
termined. <...> It is established that arc contraction does
not affect austenitic steel penetration, but it should
be <...>
The_Paton_Welding_Journal_№10_2010.pdf
International Scientific-Technical and Production Journal
October
2010
# 10
English translation of the monthly «Avtomaticheskaya Svarka» (Automatic Welding) journal published in Russian since 1948
Editor-in-Chief B.E.Paton
Yu.S.Borisov V.F.Khorunov
A.Ya.Ishchenko I.V.Krivtsun
B.V.Khitrovskaya L.M.Lobanov
V.I.Kirian A.A.Mazur
S.I.Kuchuk-Yatsenko
Yu.N.Lankin I.K.Pokhodnya
V.N.Lipodaev V.D.Poznyakov
V.I.Makhnenko K.A.Yushchenko
O.K.Nazarenko A.T.Zelnichenko
I.A.Ryabtsev
CONTENTS
SCIENTIFIC AND TECHNICAL
. and
.
Adequacy of thermohydrodynamic model of through
penetration in TIG and A-TIG welding of Nimonic-75 nickel
alloy .................................................................................................... 2
. and
. Optimal reduction of working pressure in pipelines
N.P.Alyoshin (Russia)
U.Diltey (Germany)
Guan Qiao (China)
D. von Hofe (Germany)
V.I.Lysak (Russia)
N.I.Nikiforov (Russia)
B.E.Paton (Ukraine)
Ya.Pilarczyk (Poland)
P.Seyffarth (Germany)
G.A.Turichin (Russia)
Zhang Yanmin (China)
A.S.Zubchenko (Russia)
V.N.Lipodaev, V.I.Lokteva
A.T.Zelnichenko (exec. director)
A.A.Fomin, O.S.Kurochko,
I.N.Kutianova, T.K.Vasilenko
PE «Melnik A.M.»
N.A.Dmitrieva
D.I.Sereda, T.Yu.Snegiryova
for welding repair of thinning regions ................................................... 6
. and
.
Peculiarities of arc control by external magnetic field (Review) ............. 10
. and
. Friction stir welding of aluminum alloys of different
alloying systems ................................................................................. 13
. and
. Mechanical
properties of brazed joints on dispersion-strengthened copper
alloy ................................................................................................... 17
. and
. Thermal-barrier
multilayer plasma coatings ZrO2—NiCrAlY ............................................. 22
INDUSTRIAL
. and
. and
.
Prospects of application of laser and hybrid technologies of
welding steels to increase service life of pipelines ............................... 29
. Improvement of
cyclic fatigue life of welded joints with accumulated fatigue
damage by high-frequency peening .................................................... 33
. Tendencies in development of mechanized
State Registration Certificate
KV 4790 of 09.01.2001
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This publication and each of the articles
contained herein are protected by copyright.
Permission to reproduce material contained in
this journal must be obtained in writing from
the Publisher.
Copies of individual articles may be obtained
from the Publisher.
© PWI, International Association «Welding», 2010
NEWS
Ukrainian-German Workshop «Plasma and ELectron Beam
Technologies for Protective Coatings» ................................................. 48
welding with controlled transfer of electrode metal (Review) ................ 37
BRIEF INFORMATION
. and
.
Properties of Al2O3 + Cr + TiN coatings after electron beam
treatment ........................................................................................... 45
News .................................................................................................. 47
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Стр.1
ADEQUACY OF THERMOHYDRODYNAMIC MODEL
OF THROUGH PENETRATION IN TIG
AND A-TIG WELDING OF NIMONIC-75 NICKEL ALLOY*
D.V. KOVALENKO1, D.A. PAVLYAK2, V.A. SUDNIK2 and I.V. KOVALENKO1
1E.O. Paton Electric Welding Institute, NASU, Kiev, Ukraine
2Tula State University, Tula, Russian Federation
Results of experiments on weld formation in TIG and A-TIG welding of Nimonic-75 alloy, and results of computer
simulation of the effect of convection on «sand glass» shape of weld are presented. The experiments were carried out
with and without activating flux PATIG Nim-75-A on 3.15 mm thick plates. Adequacy of the model was evaluated by
comparing the sizes of the real and simulated weld sections. The causes of recirculation flows were analyzed. Correlation
of the experimental and computation data was revealed.
Keywords: TIG and A-TIG welding, nickel alloy, penetration,
mathematical model, adequacy of mathematical model
Positive results connected with an abrupt increase of
penetration depth at activating flux deposition on the
surface of metal to be welded in TIG welding (A-TIG
process ) of titanium obtained at the E.O. Paton Electric
Welding Institute [1, 2] stimulated investigations
on arc column contraction in TIG welding of steels
and other materials [3—5].
Study [6] marked the beginning of investigations
of convection in welding. This work is devoted to the
influence of surfactants on penetration depth. Work
[7] provides experimental proof of the postulates of
[6] on the key factor in penetration depth, namely,
change of the sigh of temperature coefficient of surface
tension dσ/dT from negative to positive sign. Addition
of surfactants lowers surface tension at melting
temperature, and values of dσ/dT coefficient become
positive. However, at temperature increase up to
1900 °C, surface tension reaches values characteristic
for pure metal with a maximum at critical temperature,
and values of dσ/dT coefficient again become
negative, as for pure metal.
World’s first two-dimensional model of weld pool
convection [8], created in 1983, provided theoretical
confirmation of the postulates of [6] and showed that
Marangoni surface tension forces are predominating,
and together with the Lorentz electromagnetic forces
they are responsible for appearance of double eddy
regions. Later it was established [9] that the sign of
thermal concentration dependence of surface tension
and its values determine the direction of convective
heat transfer under the arc and number of vortices.
Simulation of the role of electromagnetic forces in
A-TIG welding is carried on, and the nature of the
mechanism of this phenomenon still has not been determined.
It is established that arc contraction does
not affect austenitic steel penetration, but it should
be taken into account as an auxiliary factor [10, 11].
It was proved here that electromagnetic convection
promotes deep penetration [12] and the centrifugal
component of the electromagnetic force is the dominating
factor of penetration [13]. Published results
are given only for the simplest axisymmetrical case of
a stationary heat source of incomplete penetration on
a stationary item from austenitic steel.
Technology of A-TIG welding of Nimonic-75 nickel
alloy was tried out for the first time at PWI [14]. It
is based on application of a short (1.5 mm) arc and
activating salt-oxide flux PATIG Nim-75-A, containing
metal fluorides and oxides. Fluorides promote arc
contraction [5] and influence development of physical
processes in it [15, 16]. Fluoride fluxes allow welding
titanium sheets of up to 8 mm thickness [17, 18]. A
team of scientists led by B.E. Paton [19] developed
a theoretical model of arc contraction by fluoride
fluxes. For sodium fluoride NaF at welding current
Iw = 100 A value of anode spot radius ra ≈ 1.5 mm
was obtained.
Another nickel alloy Nimonic-263 was welded over
a layer of isolated titanium oxides and their mixtures,
and the welding process was simulated using
PHOENICS program [20]. Calculation results differed
from experimental data.
Computer simulation has recently become the main
method of scientific investigations. Program code developers
and experimenters using such programs, face
the following question: how the error of simulation
results should be assessed? Computer simulation ends
by prediction of the result of welding, and the most
important characteristic of the prediction is the confidence
level. According to [2] prediction error is a
*Published by the materials of a paper presented at the V International Conference on Mathematical Simulation and Information
Technologies in Welding and Related Technologies (May 25—28, 2010, Katsively vil., Crimea, Ukraine).
© D.V. KOVALENKO, D.A. PAVLYAK, V.A. SUDNIK and I.V. KOVALENKO, 2010
2
10/2010
Стр.2