| 2026 №01 (05) |
DOI of Article 10.37434/as2026.01.06 |
2026 №01 (07) |
"Avtomatychne Zvaryuvannya" (Automatic Welding), #1, 2026, pp. 48-57
Dynamics of contact between parts being welded during capacitor welding of studs
D.M. Kaleko
E.O. Paton Electric Welding Institute of the NAS of Ukraine 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: dk1718@gmail.comA prerequisite for obtaining a strong connection in capacitor welding of studs is reliable excitation of the arc discharge of the capacitors, for which a thin protrusion at the end of the stud being welded serves. The source of its heating, especially the initial stage, is the subject of discussion. This mainly concerns understanding of the role of the contact electrical resistance between the parts and its transformation. The results of experiments conducted in two units that differ in the electrical characteristics of the discharge circuit made it possible to determine the role of energy parameters at the capacitor discharge initial stage and the influence of the chemical composition of the material of the parts being welded on changing the physical state of the welding zone (contact between the parts). Welding conditions can cause two different states: formation of a metallic bond of the protrusion on the stud and the sheet or a microarc gap. With a small inductance of the discharge circuit, and the associated higher rate of increase in the discharge current, the contact of the parts passes into a microarc gap in all the cases. Thus, depending on the characteristics of the discharge circuit, further heating of the protrusion up to its local destruction with excitation of the welding arc can be achieved due to Joule heating, or heating by two simultaneously acting sources - heat release in the protrusion from the current passing through it, and heat transfer from the end of the protrusion, which is heated by the arc. In the second mode, the surface of the part to which the stud is welded is cleaned of possible contaminants and decorative conductive coatings, creating conditions for producing a high-quality welded joint. 15 Ref., 2 Tabl., 10 Fig.
Keywords: stud welding, capacitor discharge, electric arc excitation, microarc discharge, contact resistance
Received: 09.06.2025
Received in revised form: 27.11.2025
Accepted: 15.01.2025
References
1. (2004) Welding Handbook, Ninth Ed. Vol. 2. Welding Processes. Pt 1. AWS.2. Paton, B.E., Zhikharev, A.M., Kaleko, D.M., Slezin, O.O. (2013) Apparatus for welding studs. Patent of Ukraine 100828, op. 01/25/2013 [in Ukrainian].
3. Trillmich, R., Welz, W. (1997) Bolzenschweißen, Grundlagen und Anwendung, Fachbuchreihe Schweißtechnik. B.133, DVS Verlag, Düsseldorf.
4. Kaleko, D.M., Lebedev, V.K., Chvertko, N.A. (1999) Processes of welding using the arc discharge of the capacitors. Welding and surfacing reviews. Harwood academic publishers.
5. Weiss, D., Franz, U., Mahrle, A., Schmidt, J. (1999) Prozessführung und Qualität beim Bolzenschweißen mit Spitzenzündung. Schweißen und Schneiden '99: Vorträge der gleichnamigen Großen Schweißtechnischen Tagung in Weimar 15-17 September 1999. DVS-Berichte, Band 204, DVS Verlag, Düsseldorf.
6. Kaleko, D., Klier, R. (2025) Einfluss der Induktivität des Entladungskreises von Kondensatoren beim Bolzenschweißen mit Spitzenzündung. Schweißen und Schneiden, 7-8, 52-59. DOI: https://doi.org/10.53192/SUS20250852
7. DSTU ISO 13918:2014 (ISO 13918:2008, IDT). Welding. Studs and ceramic bushings for arc welding of studs [in Ukrainian].
8. Kholyavko, V.V., Vladimirsky, I.A., Zhabinska, O.O. (2016) Physical properties and methods research materials. Kyiv, Tsentr uchbovoi literatury [in Ukrainian].
9. Kaleko, D.M (2019) On the problem of contact electric resistance of different-sized surfaces. The Paton Welding J., 1, 2-6. https://doi.org/10.15407/tpwj2019.01.01
10. Yakovlev, E.B., Svirina, V.V., Sergeeva, O.N. (2010) Features of metal melting during action of ultrashort laser pulses. Isv. Vusov. Priborostroenie, 53(4), 57-62 [in Russian].
11. Lauenroth, T. (2002) Prozessanalyse zum Kondensatorenentladungs- Bolzenschweßen mit Spitzezündung. Dissertation zur Erlangung des Grades eines Dr.-Ing. Technischen Universität Clausthal.
12. (1993) ASM Handbook v1. Properties and selection iron steels and high-performance alloys.
13. Kuchuk-Yatsenko, S.I. (1992) Flash-butt contact welding. Кyiv, Naukova Dumka [in Russian].
14. EN ISO 1461:2024 Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and test methods.
15. Stache, K. (1998) Prozessanalyse und Maßnahmen zur Qualitätssicherung beim Bolzenschweißen mit Spitzenzündung. Dissertation zur Erlangung des Grades eines Dr.-Ing. Technischen Universität Clausthal.
Advertising in this issue:
