International Scientific-Technical and Production Journal
May
2011
#5
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. <...> KHARLAMOV , I.V. KRIVTSUN , V.N. KORZHIK and S.V. PETROV
1
East Ukraine V. Dal National University, Lugansk, Ukraine
2
E.O. Paton Electric Welding Institute, Kiev, Ukraine
2
Suggested is a mathematical model describing the thermal state of a solid metal wire used as anode in plasma arc spraying
of coatings. <...> K e y w o r d s : plasma arc spraying, coatings, anode metal
wire, thermal state, energy balance, spraying, melting and
evaporation conditions
Heating of the wire material, its melting and formation of fine spraying particles in plasma arc spraying
occur due to the energy released in the anode spot of
the arc closed to the wire and the electric current
flowing through it, and due to the energy introduced
into the wire with the transverse flow of the arc plasma
around the wire [1]. <...> For the above reasons the productivity and stability of the plasma arc spraying process
will depend in many respects on the conditions of heat
exchange between the anode wire and heat sources
affecting it. <...> Knowledge of the main mechanisms of
heating and melting of the electrode wire in plasma
arc spraying of coatings will make it possible to develop the efficient control systems for this technological process, which will allow not only controlling the
process productivity, but also regulating the time during which metal remains in the liquid state, size of
the forming drops, etc. <...> Therefore, development of
mathematical models describing the processes that occur during heating and melting of the anode wire, as
well as mathematical modelling of the above processes
Figure 1. <...> Design diagram of the wire heating process in plasma arc
spraying: 1 – anode wire; 2 – wire nozzle; 3 – plasma torch
nozzle; 4 – plasma flow
are of high importance for further upgrading of the
plasma arc wire spraying process, increase <...>
The_Paton_Welding_Journal_№5_2011.pdf
International Scientific-Technical and Production Journal
May
2011
# 5
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.Kyrian 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
. Heating and melting of anode wire in plasma arc
spraying ....................................................................................... 2
. On the subject of electric submerged-arc
welding ......................................................................................... 8
. Strength and features of fracture of welded
joints on high-strength aluminium alloys at low
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)
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
N.A.Dmitrieva
D.I.Sereda, T.Yu.Snegiryova
temperature ................................................................................. 13
. and
. Optimisation
of the process of strengthening of welded joints of 09G2S
steel by high-frequency mechanical peening ................................ 20
. and
.
Simulation of the effect of high-voltage cables on current
ripple in welding guns with automatic bias .................................... 24
. Peculiarities of resistance welding
of copper with aluminium alloys using nanostructured foil
of Al—Cu system ........................................................................... 28
. Application of nanopowders of metals in
diffusion welding of dissimilar materials ........................................ 31
INDUSTRIAL
. and
. Manufacture of outstanding
thick-walled constructions ............................................................ 35
. and
. Efficiency of melting of electrode wire in
submerged-arc surfacing with influence of transverse
magnetic field .............................................................................. 39
State Registration Certificate
KV 4790 of 09.01.2001
$324, 12 issues per year,
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Back issues available.
All rights reserved.
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», 2011
BRIEF INFORMATION
International Scientific-Practical Seminar in Kiev ........................... 53
New Book .................................................................................... 55
. Technological peculiarities of cladding of
high alloys ................................................................................... 43
. and
. Chambers for explosion welding of metals
(Review) ...................................................................................... 47
To 130th anniversary of the first method of arc electric
welding ........................................................................................ 51
Founders:
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Editorial b
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Kharlamov M.Yu., Krivtsun I.V., Korzhik V.N
Kuzmenko V.G
Pub
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ine
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Labur T.M
International editorial c
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Nazarenko O.K., Matvejchuk V.A
Kuchuk-Yatsenko V.S
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isher:
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Стр.1
HEATING AND MELTING OF ANODE WIRE
IN PLASMA ARC SPRAYING
M.Yu. KHARLAMOV1, I.V. KRIVTSUN2, V.N. KORZHIK2 and S.V. PETROV2
1East Ukraine V. Dal National University, Lugansk, Ukraine
2E.O. Paton Electric Welding Institute, Kiev, Ukraine
Suggested is a mathematical model describing the thermal state of a solid metal wire used as anode in plasma arc spraying
of coatings. Contribution of different heat sources to the energy balance of the spraying wire is numerically investigated.
The effect of spraying parameters on the distribution of temperature in the wire, melting and evaporation of its material
is analysed.
Keywords: plasma arc spraying, coatings, anode metal
wire, thermal state, energy balance, spraying,
evaporation conditions
melting and
Heating of the wire material, its melting and formation
of fine spraying particles in plasma arc spraying
occur due to the energy released in the anode spot of
the arc closed to the wire and the electric current
flowing through it, and due to the energy introduced
into the wire with the transverse flow of the arc plasma
around the wire [1]. As a result, the efficiency of the
wire melting process substantially grows compared,
for example, to the traditional electric arc metallisation
process [1]. For the above reasons the productivity
and stability of the plasma arc spraying process
will depend in many respects on the conditions of heat
exchange between the anode wire and heat sources
affecting it. Knowledge of the main mechanisms of
heating and melting of the electrode wire in plasma
arc spraying of coatings will make it possible to develop
the efficient control systems for this technological
process, which will allow not only controlling the
process productivity, but also regulating the time during
which metal remains in the liquid state, size of
the forming drops, etc. Therefore, development of
mathematical models describing the processes that occur
during heating and melting of the anode wire, as
well as mathematical modelling of the above processes
are of high importance for further upgrading of the
plasma arc wire spraying process, increase of its productivity
and improvement of quality of the resulting
coatings.
The thermal state of the electrode wire heated by
the electric current flowing through it and heat introduced
by the electric arc has been well studied by
now. In particular, analytical expressions were derived
to determine temperature fields in a consumable
electrode during welding [2], temperature fields in a
coated electrode wire were investigated [3], heat, mass
and electric charge transfer processes in the consumable
electrode—arc—weld pool system were analysed
in detail [4, 5], etc. At the same time, peculiarities
of the additional thermal effect by the transverse
plasma flow on the consumable live wire (along with
heating by the electric arc and ohmic heating) are
insufficiently studied as yet.
The purpose of this study is to develop a mathematical
model describing thermal interaction of the
anode region of the electric arc, plasma flow and electric
current with the anode wire under conditions of
plasma arc wire spraying.
Consider the limiting-state temperature
field
Figure 1. Design diagram of the wire heating process in plasma arc
spraying: 1 – anode wire; 2 – wire nozzle; 3 – plasma torch
nozzle; 4 – plasma flow
© M.Yu. KHARLAMOV, I.V. KRIVTSUN, V.N. KORZHIK and S.V. PETROV, 2011
2
5/2011
formed in the anode wire fed at a constant speed. The
transient thermal processes related to variations or
fluctuations of the spraying process parameters, such
as plasma arc current or wire feed speed, can also be
of a certain interest. However, some quasi-stationary
temperature field forms in the wire in stable operation
of the plasma torch and wire feeder, and description
of this field will allow revealing the main mechanisms
of heating and melting of the wire during the spraying
process under investigation.
Flow diagram of the plasma arc spraying process
we used to develop the mathematical model of heating
of a live wire is shown in Figure 1. Solid wire of a
round section with radius Rw is fed to under the exit
section of the plasma torch nozzle at speed vw. It is
assumed that the electric arc formed by the plasma
torch is closed to the right end of the wire that acts
as an arc anode, the heat flow introduced into the
Стр.2