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New technology for welding aluminum and its alloys
Materials Today: Proceedings xxx (xxxx) xxx
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
New technology for welding aluminum and its alloys L.N. Bagautdinova, R.Sh. Basyrov, I.I. Galimzyanov, Al.F. Gaysin, AZ.F. Gaysin, F.M. Gaysin, I.T. Fakhrutdinova ⇑ Kazan National Research Technical University named after A. N. Tupolev – KAI, Kazan, Republic of Tatarstan, Russian Federation
a r t i c l e
i n f o
Article history: Received 21 August 2019 Accepted 30 August 2019 Available online xxxx Keywords: Fluid welding Welding technology Single-phase installation Electric discharge Low-temperature plasma Electrical steel Aluminum Duralumin
a b s t r a c t This article proposes a new approach for welding metals without the use of high-temperature arc plasma, inert gas and without filler wire. A new technological process of welding takes place with the help of an electric discharge in the electrolyte environment. The electrolyte-plasma method of welding metals allows to increase the speed in comparison with the existing market analogues, improving the quality of welding, at the same time: it saves raw materials, reagents, increases productivity. The creation of such a product corresponds to advanced production technologies and can ensure the competitiveness of domestic companies in the scientific and technical information markets and in high-tech industries. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Modern Trends in Manufacturing Technologies and Equipment 2019.
The main consumers of welding equipment are engineering, oil and gas, construction companies. Recently in Russia the European welding equipment is bought more actively; domestic welding equipment lags behind in its technological capabilities. After the collapse of the Soviet Union the scientific and technical base created by the Kiev Institute of Electric Welding named after E.O. Paton had been lost in Russia. The basis of the welding industry are arc welding machines, resistance welding machines and automated welding complexes. For welding aluminum and duralumin, only arc welding machines using inert gases and filler wires are used. The resulting weld seam is not 90% ductile and 60% not durable due to the use of high arc temperatures. Therefore, for example, in aircraft manufacturing duralumin is connected with rivets. In this regard, there is a demand for the way of welding of duralumin at low temperatures, without inert gas and filler wire, which is proposed in this work. The melting point of the oxide film is about 2044 °C, and the melting point of aluminum itself is approximately 660 °C. A low temperature is necessary for welding duralumin, at which the high-tech properties of the material are preserved. Arc welding of metals is a complex technological process that requires a cooling system and rapidly wearing high cost electrodes. ⇑ Corresponding author.
The disadvantage of arc welding of duralumin is the insufficient ductility of the weld, the likelihood of cracking, the impossibility of using the weld structure in a wet and aqueous environment, and such a weld is subject to corrosion. Currently, there is no welding method of duralumin without filler wire. In the equipment we are developing, a new approach is proposed for welding aluminum and its alloys without using high temperature arc plasma, inert gas and without filler wire. This new technological process of welding takes place with the help of an electrical discharge in an electrolyte medium [1,2]. During a short period of time (less than 1 s), there is a input of energy released due to electrical breakdown between the samples being welded and the electrolyte. The removal of the oxide film occurs under the action of the impacts of plasma and electrolyte ions. The main advantage is that welding is carried out at a low electrolyte temperature (up to 80 °C) and welded materials (up to 700 °C), which provide durable (up to 90–95%), ductile and corrosion-resistant weld seam. Currently, there is no welding of duralumin without filler wire. Known methods with filler wire use complex equipment, a long preparation time (preliminary heating, etching, roasting of electrodes). These methods are energy intensive and technologically complex.
E-mail address: [email protected] (I.T. Fakhrutdinova). https://doi.org/10.1016/j.matpr.2019.08.239 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Modern Trends in Manufacturing Technologies and Equipment 2019.
Please cite this article as: L. N. Bagautdinova, R. S. Basyrov, I. I. Galimzyanov et al., New technology for welding aluminum and its alloys, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.239
2
L.N. Bagautdinova et al. / Materials Today: Proceedings xxx (xxxx) xxx
temperature arc plasma, inert gas and without filler wire. This new technological process of welding takes place with the help of an electrical discharge in an electrolyte medium. During a short period of time (less than 1 s), there is a input of energy released due to electrical breakdown between the samples being welded and the electrolyte. The removal of the oxide film occurs under the action of the impacts of plasma and electrolyte ions. The main advantage is that welding is carried out at a low electrolyte temperature (up to 80 °C) and welded materials (up to 700 °C), which provide durable (up to 90–95%), ductile and corrosion-resistant weld seam. Fig. 1 shows the elements of welding duralumin. Fig. 2 shows a pilot equipment with a power source 1 and an electrolytic bath 2 for welding aluminum and its alloys. References Fig. 1. Samples of duralumin D16, welded by the method of electrolytic-plasma welding in liquid.
[1] Gaisin Al.F. Model of a glow discharge between an electrolytic anode and a metal cathode. R.Sh. Basyrov, Al. F. Gaisin, E.E. Sleep. High Temperature. Thermal physics of high temperatures, M., 2015, T. 53, №2, p. 188–192. [2] Gaisin Al.F. Spectral diagnostics of plasma discharge between a metal cathode and a liquid anode, Al.F. Gaisin, E.E. Son, A.V. Efimov, A.Kh. Gilmutdinov, N.F. Kashapov. High Temperature Thermal Engineering, 2017, T.55, Number 3, p. 472–475. [3] Patent 2625145 Russian Federation: IPC W23K 9/23 (2006.01), W23K 28/02 (2014.01), W23K 103/10 (2006.01). The method of electrolytic-plasma welding of products from aluminum and its alloys / Gaisin Al.F., the applicant and patentee: Kazan National Research Technical University nam. after A.N. Tupolev - KAI. - № 2016112060, Appl. 03/30/2016; publ. 11.07. 2017, Bull. №20.
Fig. 2. Pilot equipment for welding aluminum and its alloys.
In the equipment we are developing [3], a new approach is proposed for welding aluminum and its alloys without using high
Please cite this article as: L. N. Bagautdinova, R. S. Basyrov, I. I. Galimzyanov et al., New technology for welding aluminum and its alloys, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.239
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
New technology for welding aluminum and its alloys L.N. Bagautdinova, R.Sh. Basyrov, I.I. Galimzyanov, Al.F. Gaysin, AZ.F. Gaysin, F.M. Gaysin, I.T. Fakhrutdinova ⇑ Kazan National Research Technical University named after A. N. Tupolev – KAI, Kazan, Republic of Tatarstan, Russian Federation
a r t i c l e
i n f o
Article history: Received 21 August 2019 Accepted 30 August 2019 Available online xxxx Keywords: Fluid welding Welding technology Single-phase installation Electric discharge Low-temperature plasma Electrical steel Aluminum Duralumin
a b s t r a c t This article proposes a new approach for welding metals without the use of high-temperature arc plasma, inert gas and without filler wire. A new technological process of welding takes place with the help of an electric discharge in the electrolyte environment. The electrolyte-plasma method of welding metals allows to increase the speed in comparison with the existing market analogues, improving the quality of welding, at the same time: it saves raw materials, reagents, increases productivity. The creation of such a product corresponds to advanced production technologies and can ensure the competitiveness of domestic companies in the scientific and technical information markets and in high-tech industries. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Modern Trends in Manufacturing Technologies and Equipment 2019.
The main consumers of welding equipment are engineering, oil and gas, construction companies. Recently in Russia the European welding equipment is bought more actively; domestic welding equipment lags behind in its technological capabilities. After the collapse of the Soviet Union the scientific and technical base created by the Kiev Institute of Electric Welding named after E.O. Paton had been lost in Russia. The basis of the welding industry are arc welding machines, resistance welding machines and automated welding complexes. For welding aluminum and duralumin, only arc welding machines using inert gases and filler wires are used. The resulting weld seam is not 90% ductile and 60% not durable due to the use of high arc temperatures. Therefore, for example, in aircraft manufacturing duralumin is connected with rivets. In this regard, there is a demand for the way of welding of duralumin at low temperatures, without inert gas and filler wire, which is proposed in this work. The melting point of the oxide film is about 2044 °C, and the melting point of aluminum itself is approximately 660 °C. A low temperature is necessary for welding duralumin, at which the high-tech properties of the material are preserved. Arc welding of metals is a complex technological process that requires a cooling system and rapidly wearing high cost electrodes. ⇑ Corresponding author.
The disadvantage of arc welding of duralumin is the insufficient ductility of the weld, the likelihood of cracking, the impossibility of using the weld structure in a wet and aqueous environment, and such a weld is subject to corrosion. Currently, there is no welding method of duralumin without filler wire. In the equipment we are developing, a new approach is proposed for welding aluminum and its alloys without using high temperature arc plasma, inert gas and without filler wire. This new technological process of welding takes place with the help of an electrical discharge in an electrolyte medium [1,2]. During a short period of time (less than 1 s), there is a input of energy released due to electrical breakdown between the samples being welded and the electrolyte. The removal of the oxide film occurs under the action of the impacts of plasma and electrolyte ions. The main advantage is that welding is carried out at a low electrolyte temperature (up to 80 °C) and welded materials (up to 700 °C), which provide durable (up to 90–95%), ductile and corrosion-resistant weld seam. Currently, there is no welding of duralumin without filler wire. Known methods with filler wire use complex equipment, a long preparation time (preliminary heating, etching, roasting of electrodes). These methods are energy intensive and technologically complex.
E-mail address: [email protected] (I.T. Fakhrutdinova). https://doi.org/10.1016/j.matpr.2019.08.239 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Modern Trends in Manufacturing Technologies and Equipment 2019.
Please cite this article as: L. N. Bagautdinova, R. S. Basyrov, I. I. Galimzyanov et al., New technology for welding aluminum and its alloys, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.239
2
L.N. Bagautdinova et al. / Materials Today: Proceedings xxx (xxxx) xxx
temperature arc plasma, inert gas and without filler wire. This new technological process of welding takes place with the help of an electrical discharge in an electrolyte medium. During a short period of time (less than 1 s), there is a input of energy released due to electrical breakdown between the samples being welded and the electrolyte. The removal of the oxide film occurs under the action of the impacts of plasma and electrolyte ions. The main advantage is that welding is carried out at a low electrolyte temperature (up to 80 °C) and welded materials (up to 700 °C), which provide durable (up to 90–95%), ductile and corrosion-resistant weld seam. Fig. 1 shows the elements of welding duralumin. Fig. 2 shows a pilot equipment with a power source 1 and an electrolytic bath 2 for welding aluminum and its alloys. References Fig. 1. Samples of duralumin D16, welded by the method of electrolytic-plasma welding in liquid.
[1] Gaisin Al.F. Model of a glow discharge between an electrolytic anode and a metal cathode. R.Sh. Basyrov, Al. F. Gaisin, E.E. Sleep. High Temperature. Thermal physics of high temperatures, M., 2015, T. 53, №2, p. 188–192. [2] Gaisin Al.F. Spectral diagnostics of plasma discharge between a metal cathode and a liquid anode, Al.F. Gaisin, E.E. Son, A.V. Efimov, A.Kh. Gilmutdinov, N.F. Kashapov. High Temperature Thermal Engineering, 2017, T.55, Number 3, p. 472–475. [3] Patent 2625145 Russian Federation: IPC W23K 9/23 (2006.01), W23K 28/02 (2014.01), W23K 103/10 (2006.01). The method of electrolytic-plasma welding of products from aluminum and its alloys / Gaisin Al.F., the applicant and patentee: Kazan National Research Technical University nam. after A.N. Tupolev - KAI. - № 2016112060, Appl. 03/30/2016; publ. 11.07. 2017, Bull. №20.
Fig. 2. Pilot equipment for welding aluminum and its alloys.
In the equipment we are developing [3], a new approach is proposed for welding aluminum and its alloys without using high
Please cite this article as: L. N. Bagautdinova, R. S. Basyrov, I. I. Galimzyanov et al., New technology for welding aluminum and its alloys, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.239