The Paton Welding Journal, 2021, #6, 41-47 pages
Restoration of worn helical coarse pitch gears by electroslag cladding
S.M. Kozulin1, I.I. Lychko1, S.S. Kovalchuk1, G.S. Podyma2 and M.V. Lazarchuk2
E.O. Paton Electric Welding Institute of the NAS of Ukraine
11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: email@example.com
National Technical University of Ukraine «Igor Sikorsky Kyiv Polytechnic Institute»
6/2 Dashavska Str., 03506, Kyiv, Ukraine. E-mail: firstname.lastname@example.org
The paper presents the results of experimental studies performed with the aim of development of a high-efficient
technology, equipment and special technological fixtures for restoration of worn teeth of coarse pitch helical gears by
electroslag cladding (ESC). The main objectives of the work were development of the design and method of fabrication
of a special water-cooled forming fixture, establishing ESC modes that guarantee fusion of the filler with the base
metal, as well as sound formation of the working surfaces of clad teeth; adaptation of the assemblies of batch-produced
machine A-535 UKhL4 with TShS 1000-3 power source to perform consumable-nozzle ESC by 3 mm electrode wire
using AN-8 and AN-9U fused fluxes; restoration of a test-standard helical gear and evaluation of its serviceability. The
level of specific heat input providing a sound teeth restoration was established; welding consumables were selected
to provide the required chemical composition and service characterisitcs of the clad metal. A special shop section for
restoration of the teeth of coarse pitch gears was set up at repair-mechanical plant of TPA «Bratsk TIC», where a gear
wheel was restored using ESC and sent for performance tests. Operation experience showed that the restored gear
wheel has good running smoothness and teeth resistance under the conditions of alternating and contact loads, arising
at operation of the dedebarking drum. Teeth wear on the level of the generating circle is not more than 3‒5 mm. 10 Ref.,
1 Table, 8 Figures.
restoration, helical coarse pitch gears, wear, electroslag cladding, consumable nozzle, specific heat
input, forming fixture, cladding machine, heat treatment, residual deformations, performance tests
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