2021 №06 (06) DOI of Article
2021 №06 (01)

The Paton Welding Journal 2021 #06
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

1E.O. Paton Electric Welding Institute of the NAS of Ukraine 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail:
2National Technical University of Ukraine «Igor Sikorsky Kyiv Polytechnic Institute» 6/2 Dashavska Str., 03506, Kyiv, Ukraine. E-mail:

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.
Keywords: restoration, helical coarse pitch gears, wear, electroslag cladding, consumable nozzle, specific heat input, forming fixture, cladding machine, heat treatment, residual deformations, performance tests

Received 13.04.2021


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