The Paton Welding Journal, 2026, №10

2026 №10 (02)

2026 №10 (04)

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The Paton Welding Journal, 2026, #10, 30-38 pages

Effect of resistance butt welding parameters on the formation of dissimilar nickel superalloy joints

I.V. Ziakhor, A.M. Levchuk, A.O. Nakonechnyi, Yu.A. Shylo, M.S. Zavertannyi, H.V. Hushchyn, V.V. Koltsov

E.O. Paton Electric Welding Institute of the NASU. 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: zyakhor2@ukr.net

Abstract
An urgent problem in the manufacture of welded components of aircraft engines is the development of effective technologies for solid-state joining of nickel superalloys (NS). The work investigated the features of the formation of dissimilar joints during resistance butt welding (RBW) of NS grades VZhL12U and EI698VD, which are used by domestic manufacturers of aircraft gas turbine engines. The microstructure of joints obtained by RBW at different values of technological parameters with one- and two-stage pressure application cycles was studied, in particular, using an intermediate element (IE) in the form of a nichrome alloy (Ni80/Cr20) foil. It was established that with RBW the main problem is to ensure a heat release uniform over the cross-section and localized along the length in the contact zone of workpieces, which is due to the specific temperature dependence of the NS thermophysical characteristics. The increase in the temperature of the metal in the contact zone is accompanied by a decrease in its specific electrical resistance, which is associated with the dissolution of the γʹ-phase during the heating process. The microstructure of the joints of the VZhL12U and EI698VD alloys obtained by RBW is characterized by the presence of a cast core with a dendritic microstructure and defects of the “lack-of-penetration” type in the peripheral part of the cross-section of the welded workpieces. The use of an IE and an increase in the intensity of the deformation effect at the upset stage ensure the localization of contact heating and the displacement of the molten metal beyond the cross-section of the workpieces. The formation of a defect-free joint over the entire cross-section was ensured by the crystallization of a shared cast core under intense plastic deformation during the RBW upsetting stage. Studies of the morphology of the γʹ-phase in the partial melting zone have shown that short-term heating to a temperature exceeding the solvus value does not lead to the dissolution of the γʹ-phase in unmelted grains of the VZhL12U alloy. A comparison of the obtained results with the data on the complete dissolution of the γʹ-phase particles during friction welding of the VZhL12U and EI698VD alloys indicates a significant role of plastic deformation in the formation of the phase composition of NS welded joints.
Keywords: nickel superalloy, pressure butt welding, resistance butt welding, intermediate element, welded joint, microstructure, dendritic microstructure, γʹ-phase, microhardness

Received: 22.06.2026
Received in revised form: 06.08.2026
Accepted: 30.10.2026

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Suggested Citation

I.V. Ziakhor, A.M. Levchuk, A.O. Nakonechnyi, Yu.A. Shylo, M.S. Zavertannyi, H.V. Hushchyn, V.V. Koltsov (2026) Effect of resistance butt welding parameters on the formation of dissimilar nickel superalloy joints. The Paton Welding J., 10, 30-38.

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