ISSN 0491-6441
Journal "Svarochnoe Proizvodstvo"
Contents of the current issue (No. 01 2026)
2.5.8 WELDING, RELATED PROCESSES AND TECHNOLOGIES
UDC 621.791.927
DOI: 10.34661/SP.2026.1076.1.001
L. K. Leshchinsky, V. P. Ivanov, V. N. Matvienko, M. V. Ivanov —
Reducing the unevenness of penetration depth in submerged arc surfacing with a strip electrode
It is shown that in submerged arc surfacing with a strip electrode, the shunting of the arc by the weld pool melt and the movement of the arc along the electrode end, depending on the current magnitude, determine the unevenness of base metal penetration, which, along with the shallow penetration depth, is characteristic when using strip electrodes with a thickness of less than 0.5 mm.
Keywords: surfacing, strip electrode, penetration depth, unevenness, weld pool, local overheating, grain size, additional filler strip, impact toughness
DOI: 10.34661/SP.2026.1076.1.001
L. K. Leshchinsky, V. P. Ivanov, V. N. Matvienko, M. V. Ivanov —
Reducing the unevenness of penetration depth in submerged arc surfacing with a strip electrode
It is shown that in submerged arc surfacing with a strip electrode, the shunting of the arc by the weld pool melt and the movement of the arc along the electrode end, depending on the current magnitude, determine the unevenness of base metal penetration, which, along with the shallow penetration depth, is characteristic when using strip electrodes with a thickness of less than 0.5 mm.
Keywords: surfacing, strip electrode, penetration depth, unevenness, weld pool, local overheating, grain size, additional filler strip, impact toughness
2.5.8 SCIENTIFIC AND TECHNICAL SECTION
UDC 621.791.011
DOI: 10.34661/SP.2026.1076.1.002
V. N. Semykin, D. A. Sviridov, V. N. Protsenko, A. V. Besko, G. G. Kosarev —
Application areas of the magnetoelastic method (Review)
The article considers examples of effective use of the non-destructive physical magnetoelastic method for monitoring residual stresses and fatigue strength in mechanical engineering, construction, shipbuilding, pipelines, as well as in research practice.
Keywords: welded joints, residual stresses, magnetoelastic method, isostats
UDC 621.313.13:621.314.571.00.24
DOI: 10.34661/SP.2026.1076.1.003
F. R. Ismagilov, I. F. Yangirov, A. R. Khalikov, A. M. Kabirov, N. S. Kudryavtsev —
High-voltage pulse generator based on a double-spiral magnetocumulative generator with improved characteristics for welding operations
The paper proposes an original design of a high-voltage electromechanical double-spiral voltage source based on a magnetocumulative generator and a voltage multiplier with improved characteristics. The issue of the possibility of using the installation for welding operations, namely for spot welding, is considered.
Keywords: magnetocumulative generator, multiplier, electric explosion, modeling, liner, double-spiral solenoid, oscillatory process
UDC 621.791
DOI: 10.34661/SP.2026.1076.1.004
N. I. Ivanov, S. A. Chevychelov —
Quality control of resistance projection welding of intercell connections of lead-acid batteries
A device for automatic quality control of resistance welding of lead-antimony terminal posts of an intercell connection through a hole in the intercell partition of a monoblock made of polymeric material of a lead-acid battery is described. The device uses continuous measurement of the voltage drop across the electrodes during the welding process. When a specified threshold value is reached, which is set by the device as a value linearly decreasing over time, the welding current is switched off. The duration of the current flow is determined and compared with the boundary values of the permissible time interval. In case of deviation from these values, the unsatisfactory quality of the connection is established and it is rejected. The results of an experimental study of the technological features of the process with automatic quality control of intercell connection welding are presented.
Keywords: resistance welding, intercell connection, battery, current pulse, linearly decreasing threshold voltage, permissible time interval, device
DOI: 10.34661/SP.2026.1076.1.002
V. N. Semykin, D. A. Sviridov, V. N. Protsenko, A. V. Besko, G. G. Kosarev —
Application areas of the magnetoelastic method (Review)
The article considers examples of effective use of the non-destructive physical magnetoelastic method for monitoring residual stresses and fatigue strength in mechanical engineering, construction, shipbuilding, pipelines, as well as in research practice.
Keywords: welded joints, residual stresses, magnetoelastic method, isostats
UDC 621.313.13:621.314.571.00.24
DOI: 10.34661/SP.2026.1076.1.003
F. R. Ismagilov, I. F. Yangirov, A. R. Khalikov, A. M. Kabirov, N. S. Kudryavtsev —
High-voltage pulse generator based on a double-spiral magnetocumulative generator with improved characteristics for welding operations
The paper proposes an original design of a high-voltage electromechanical double-spiral voltage source based on a magnetocumulative generator and a voltage multiplier with improved characteristics. The issue of the possibility of using the installation for welding operations, namely for spot welding, is considered.
Keywords: magnetocumulative generator, multiplier, electric explosion, modeling, liner, double-spiral solenoid, oscillatory process
UDC 621.791
DOI: 10.34661/SP.2026.1076.1.004
N. I. Ivanov, S. A. Chevychelov —
Quality control of resistance projection welding of intercell connections of lead-acid batteries
A device for automatic quality control of resistance welding of lead-antimony terminal posts of an intercell connection through a hole in the intercell partition of a monoblock made of polymeric material of a lead-acid battery is described. The device uses continuous measurement of the voltage drop across the electrodes during the welding process. When a specified threshold value is reached, which is set by the device as a value linearly decreasing over time, the welding current is switched off. The duration of the current flow is determined and compared with the boundary values of the permissible time interval. In case of deviation from these values, the unsatisfactory quality of the connection is established and it is rejected. The results of an experimental study of the technological features of the process with automatic quality control of intercell connection welding are presented.
Keywords: resistance welding, intercell connection, battery, current pulse, linearly decreasing threshold voltage, permissible time interval, device
2.5.8 PRODUCTION SECTION
UDC 621.791
DOI: 10.34661/SP.2026.1076.1.005
D. S. Belov, A. I. Nikolin —
Experimental technology for repairing worn switch frogs by laser powder cladding
A laser powder cladding technology has been developed for the rapid restoration of worn switch frogs (steel G13L) within short technological windows (~40 min.). Unlike traditional methods, it is aimed at minimizing thermal impact and deformation. Experimental studies on specimens with damage up to 450 mm in length and 15 mm in depth confirmed the effectiveness of the technological process, which includes abrasive preparation, layer-by-layer cladding, and finishing treatment. Metallographic analysis showed the formation of a homogeneous, pore-free deposited layer with an austenitic structure reinforced with dispersed carbides. The measured hardness of the deposited metal (268–273 HV) and the heat-affected zone (297–310 HV) fully comply with the requirements of OJSC Russian Railways. The results obtained demonstrate the potential of the technology for field application and serve as a basis for transitioning to full-scale testing.
Keywords: switch frog, G13L steel, technological window, restoration technology, laser powder cladding
UDC 621.791.14, 621.9.01
DOI: 10.34661/TM.2025.280.10.065
L. S. Vasiliev, M. A. Lukin, I. P. Nikiforov, D. V. Grinev —
Friction welding of bimetallic materials in the manufacture of a boring bar with increased rigidity and vibration resistance*
The paper investigates the possibility and effectiveness of using rotary friction welding for joining bimetallic materials used to manufacture a designed boring bar with increased rigidity and vibration resistance. Materials exhibiting a significant difference in mechanical and technological properties are welded — corrosion-resistant steel 40Kh13 and carbon steels (St. 3 and steel 40). It is shown that the bimetallic bar with preliminary internal stresses made of 40Kh13 and St. 3 steels is inferior in static and dynamic characteristics to a similar solid heat-treated bar made of 40Kh13 steel. The improved bar made of 40Kh13 steel and structural carbon steel 40 significantly exceeds the similar solid bar in static and dynamic parameters. Metallographic studies and frequency analysis were carried out.
Keywords: boring bar, preliminary internal stresses, rotary friction welding, metallographic studies, frequency analysis
UDC 621.791
DOI: 10.34661/SP.2026.1076.1.006
F. E. Doroshenko —
Mechanization of welding of process and urban pipelines
The results of the development of automated and mechanized welding technologies for process and urban pipelines using modern welding materials and small-scale mechanization tools are presented. The advantages of metal-cored wires compared to solid wires in making the root pass of non-rotatable pipeline joints are shown. The main provisions of the technology of automated pipe welding with rutile flux-cored wire without transverse oscillations of the torch using orbital magnetic carriages are outlined.
Keywords: process pipelines, mechanized and automated welding, metal-cored wire, rutile wire, orbital magnetic carriages
DOI: 10.34661/SP.2026.1076.1.005
D. S. Belov, A. I. Nikolin —
Experimental technology for repairing worn switch frogs by laser powder cladding
A laser powder cladding technology has been developed for the rapid restoration of worn switch frogs (steel G13L) within short technological windows (~40 min.). Unlike traditional methods, it is aimed at minimizing thermal impact and deformation. Experimental studies on specimens with damage up to 450 mm in length and 15 mm in depth confirmed the effectiveness of the technological process, which includes abrasive preparation, layer-by-layer cladding, and finishing treatment. Metallographic analysis showed the formation of a homogeneous, pore-free deposited layer with an austenitic structure reinforced with dispersed carbides. The measured hardness of the deposited metal (268–273 HV) and the heat-affected zone (297–310 HV) fully comply with the requirements of OJSC Russian Railways. The results obtained demonstrate the potential of the technology for field application and serve as a basis for transitioning to full-scale testing.
Keywords: switch frog, G13L steel, technological window, restoration technology, laser powder cladding
UDC 621.791.14, 621.9.01
DOI: 10.34661/TM.2025.280.10.065
L. S. Vasiliev, M. A. Lukin, I. P. Nikiforov, D. V. Grinev —
Friction welding of bimetallic materials in the manufacture of a boring bar with increased rigidity and vibration resistance*
The paper investigates the possibility and effectiveness of using rotary friction welding for joining bimetallic materials used to manufacture a designed boring bar with increased rigidity and vibration resistance. Materials exhibiting a significant difference in mechanical and technological properties are welded — corrosion-resistant steel 40Kh13 and carbon steels (St. 3 and steel 40). It is shown that the bimetallic bar with preliminary internal stresses made of 40Kh13 and St. 3 steels is inferior in static and dynamic characteristics to a similar solid heat-treated bar made of 40Kh13 steel. The improved bar made of 40Kh13 steel and structural carbon steel 40 significantly exceeds the similar solid bar in static and dynamic parameters. Metallographic studies and frequency analysis were carried out.
Keywords: boring bar, preliminary internal stresses, rotary friction welding, metallographic studies, frequency analysis
UDC 621.791
DOI: 10.34661/SP.2026.1076.1.006
F. E. Doroshenko —
Mechanization of welding of process and urban pipelines
The results of the development of automated and mechanized welding technologies for process and urban pipelines using modern welding materials and small-scale mechanization tools are presented. The advantages of metal-cored wires compared to solid wires in making the root pass of non-rotatable pipeline joints are shown. The main provisions of the technology of automated pipe welding with rutile flux-cored wire without transverse oscillations of the torch using orbital magnetic carriages are outlined.
Keywords: process pipelines, mechanized and automated welding, metal-cored wire, rutile wire, orbital magnetic carriages
2.2.8. METHODS AND INSTRUMENTS FOR CONTROL AND DIAGNOSTICS OF MATERIALS AND PRODUCTS
UDC 621.791.75; 621.314
DOI: 10.34661/SP.2026.1076.1.007
V. V. Burlaka, S. V. Gulakov, A. Yu. Golovin, K. Yu. Mironova —
A module for collecting information on the electrical parameters of power sources for arc welding*
The article presents the design and the schematic circuit diagram of a module for collecting information on the electrical parameters of power sources for arc welding, which allows analyzing and forming a quantitative assessment of the quality of the arc welding process, evaluating the qualifications of welders, as well as the properties of welding materials and welding equipment. Experiments confirming the compliance of the device's actual parameters with the specified ones have been carried out.
Keywords: arc welding, parameter measurement, power source, volt-ampere characteristic, welding quality
DOI: 10.34661/SP.2026.1076.1.007
V. V. Burlaka, S. V. Gulakov, A. Yu. Golovin, K. Yu. Mironova —
A module for collecting information on the electrical parameters of power sources for arc welding*
The article presents the design and the schematic circuit diagram of a module for collecting information on the electrical parameters of power sources for arc welding, which allows analyzing and forming a quantitative assessment of the quality of the arc welding process, evaluating the qualifications of welders, as well as the properties of welding materials and welding equipment. Experiments confirming the compliance of the device's actual parameters with the specified ones have been carried out.
Keywords: arc welding, parameter measurement, power source, volt-ampere characteristic, welding quality
INFORMATION
UDC 621.002
Trends in the development of electron beam technologies: based on the proceedings of the 6th International Conference "Electron Beam Welding and Related Technologies"
Trends in the development of electron beam technologies: based on the proceedings of the 6th International Conference "Electron Beam Welding and Related Technologies"