E.O. Paton Electric Welding Institute of the National Academy of Sciences of Ukraine
International Scientific-Technical and Production Journal
March 2016
No. 3
Published since 2000
English translation of the monthly «Avtomaticheskaya Svarka» (Automatic Welding) journal published in Russian since 1948
EDITORIAL BOARD
Editor-in-Chief
B.E. Paton
Scientists of PWI, Kiev
S.I. Kuchuk-Yatsenko (vice-chief ed.),
V.N. Lipodaev (vice-chief ed.),
Yu.S. Borisov, G.M. Grigorenko,
A.T. Zelnichenko, V.V. Knysh,
I.V. Krivtsun, Yu.N. Lankin,
L.M. Lobanov, V.D. Poznyakov,
I.A. Ryabtsev, V.F. Khorunov,
K.A. Yushchenko
Scientists of Ukrainian Universities
M.N. Brykov, ZNTSU, Zaporozhie
V.V. Dmitrik, NTU «KhPI», Kharkov
V.V. Kvasnitsky, NSU, Nikolaev
V.D. Kuznetsov, NTUU «KPl», Kiev
Foreign Scientists
N.P. Alyoshin
N.E. Bauman MSTU, Moscow, Russia
Guan Qiao
Beijing Aeronautical Institute, China
A.S. Zubchenko
DB «Gidropress», Podolsk, Russia
M. Zinigrad
College of Judea & Samaria, Ariel, Israel
V.I. Lysak
Volgograd STU, Russia
Ya. Pilarczyk
Welding Institute, Gliwice, Poland
U. Reisgen
Welding and Joining Institute, Aachen, Germany
O.I. Steklov
Welding Society, Moscow, Russia
G.A. Turichin
St. Petersburg SPU, Russia
Founders
E.O. Paton Electric Welding Institute, NASU
International Association «Welding»
Publisher
International Association «Welding»
Translators
A.A. Fomin, O.S. Kurochko, I.N. Kutianova
Editor
N.A. Dmitrieva
Electron galley
D.I. Sereda, T.Yu. Snegiryova
Address
E.O. Paton Electric Welding Institute,
International Association «Welding»
11 Kazimir Malevich Str. (former Bozhenko Str.),
03680, Kiev, Ukraine
Tel.: (38044) 200 60 16, 200 82 77
Fax: (38044) 200 82 77, 200 81 45
E-mail: journal@paton.kiev.ua
www.patonpublishinghouse.com
State Registration Certificate
KV 4790 of 09.01.2001
ISSN 0957-798X
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© PWI, International Association «Welding», 2016
CONTENTS
SCIENTIFIC AND TECHNICAL
Egerland S., Zimmer J., Brunmaier R., Nussbaumer R.,
Posch G. and Rutzinger B. Advanced gas tungsten arc welding
(surfacing) current status and application .................................... 2
Knysh V.V., Solovej S.A., Nyrkova L.I., Shitova L.G. and
Rybakov A.A. Improvement of cyclic fatigue life of tee welded
joints by high-frequency mechanical peening under the
conditions of higher humidity and temperature ............................ 12
Lebedev V.A., Lendel I.V., Yarovitsyn A.V., Los E.I. and
Dragan S.V. Peculiarities of formation of structure of welded
joints in arc surfacing with pulse feed of electrode wire .............. 18
Lukashevich A.A. Calculation-experimental method for
determination of spectrum components of non-stationary
loading of carbon steel welded joint ............................................ 24
INDUSTRIAL
Tsaryuk A.K., Skulsky V.Yu., Nimko M.A., Gubsky A.N.,
Vavilov A.V. and Kantor A.G. Improvement of the technology of
welding high-temperature diaphragms in steam turbine flow
section ......................................................................................... 28
Kulik V.M., Osadchuk S.A., Nyrkova L.I., Elagin V.P. and
Melnichuk S.L. Extension of service life of welded tanks of
stainless steel by increasing pitting resistance ............................ 37
Olejnik O.I., Maksimov S.Yu., Paltsevich A.P. and
Goncharenko E.I. Development of technology of mechanized
arc welding in repair of pressurized main gas pipeline ................ 42
Vasilev Yu.S., Olejnik N.I. and Parshutina L.S. Development of
adhesion and adhesion-welding technology for repair of bearing
seats for extension of service life of casing parts of power
equipment .................................................................................... 49
INFORMATION
On the 100th
anniversary of Boris I. Medovar .............................. 54
Стр.1
SCIENTIFIC AND TECHNICAL
doi.org/10.15407/tpwj2016.03.01
ADVANCED GAS TUNGSTEN ARC WELDING (SURFACING)
CURRENT STATUS AND APPLICATION
S. EGERLAND, J. ZIMMER, R. BRUNMAIER, R. NUSSBAUMER, G. POSCH and B. RUTZINGER
Fronius International GmbH, Wels, Austria. E-mail: egerland.stephan@fronius.com
Gas Shielded Tungsten Arc Welding (GTAW) — a process well-known providing highest quality weld results joined though
by lower performance. Gas metal arc welding is frequently chosen to increase productivity along with broadly accepted
quality. Those industry segments, especially required to produce high quality corrosion-resistant surfacing, e.g. applying
nickel-based filler materials, are regularly in consistent demand to comply with «zero defect» criteria. In this conjunction
weld performance limitations are overcome employing advanced «hot-wire» GTAW systems. This paper, from a
welding automation perspective, describes the technology of such devices and deals with the current status is this field,
namely the application of dual-cathode hot-wire electrode GTAW cladding, considerably broadening achievable limits.
27 Ref., 2 Tables, 14 Figures.
Keywords: GTAW (cladding), single-cathode GTAW, hot-wire welding, dual-cathode GTAW
Arc welding, to the widest extent, is suggested utilised
for fusion welding. The major remainder, i.e. weld surfacing,
is supposed reasonably split into «hardfacing»
and «corrosion-resistant» weld overlay [1, 2]. Economic
considerations drive manufacturers to apply
high performance surfacing processes, such as submerged-arc
welding or resistance electroslag welding.
Although producing broadly acceptable quality, these
processes are specifically limited respectively due to
compulsory use of flux (limited out-of-position capabilities),
high dilution, or undesirable aspect ratios.
Controlled gas metal arc welding processes (e.g.
CMT method) have been introduced to the industry
coping with dilution related issues, e.g. corrosion [3],
and thereby partially replacing submerged-arc and resistance
electroslag welding. Surfacing applications
exist, however, defining «zero defect» criteria paramount
to prevent complicated rework, sustainably
assure highest surfacing performance and maintaining
long-term component durability. Though joined by
limited performance in arc efficiency and weld deposition
rate, gas shielded tungsten arc welding (GTAW)
is frequently applied in such cases. To overcome lack of
performance, systems have been developed modifying
the wire feeding process hereby leading to either «coldwire»
or «hot-wire» GTAW. While the former was early
revealing process instabilities and noticeably rather difficult
deployable [4, 5], the latter appeared capable of
tackling inconsistencies, mainly, by preheating the wire.
Manz [6] early described the advantages, e.g. a
significant increase in weld deposition rate through
beneficially using the resistive wire heating and, compared
with cold-wire GTAW, hereby achieving wire
feed rates 3 to 10 times faster into the weld pool [4].
Hot-wire GTAW systems continuously advanced are
nowadays well-accepted because of providing user
benefits [2, 7, 8]. Information on the operational relationship
applying hot-wire and cold-wire GTAW is
given in [6] and according to this author proper parameter
set up would even allow the deposition of wire
without any additional arc. This is due to electrical
resistive heating of the wire of a specific composition
and diameter according to [6]
I2
R = I2
Lρ/d2
(π/4),
(1)
where ρ is the apparent resistivity of the wire material;
L is the effective wire extension length; and d is
the wire diameter. The energy required for melting the
wire can be expressed as
Emelt
= HFδd2
(π/4),
(2)
where H is the heat content of the liquid wire volume; F
is the wire feed rate; and δ is the apparent wire density.
Figure 1 adopted from [6] schematically depicts the
Figure 1. Schematic of hot-wire GTAW system [6]: 1 — GTAW
power supply (CC mode); 2 — nozzle; 3 — tungsten electrode;
4 — contact tube; 5 — filler wire; 6 — wire feeder; 7 — feed
rolls; 8 — wire reel; 9 — hot wire power supply (CV mode)
2
hot-wire GTAW principle.
Wire feed rate can be computed as
F = I2
L(ES)/(πd2
/4).
© S. EGERLAND, J. ZIMMER, R. BRUNMAIER, R. NUSSBAUMER, G. POSCH and B. RUTZINGER, 2016
ISSN 0957-798X THE PATON WELDING JOURNAL, No. 3, 2016
(3)
ES is here referred to as the «extension sensitivity
constant» [6] dependent only on the wire material
Стр.2