2016 №06 (24) DOI of Article
2016 №06 (26)

The Paton Welding Journal 2016 #06
The Paton Welding Journal, 2016, #5-6, 143-149 pages

Dependencies of discrete-additive formation of microvolumes of metal being solidified in multi-layer microplasma powder surfacing of nickel alloys

K.A. Yushchenko, A.V. Yarovitsyn And N.O. Chervyakov

E.O. Paton Electric Welding Institute, NASU 11 Kazimir Malevich Str., 03680, Kiev, Ukraine. E-mail:

Peculiarities of heat input, bead cross-section area and efficiency were investigated at single-layer microplasma powder surfacing of nickel heat-resistant alloy JS32 on narrow substrate of 1–2 mm thickness. It is determined that series of its modes using 5–15 A welding current differs by the minimum heat input. Calculated evaluation of stress-strain state of a welded joint was carried out for its minimum and maximum level during building-up of edge of a plate using single- and three-layer surfacing. It is shown that the value of heat input in microplasma surfacing determines a width of plastic deformation zone and value of sum plastic deformations as a result of reheating in multi-layer surfacing. New technological principles were proposed for selecting the modes of multi-layer and 3D-microplasma powder surfacing of the parts from nickel heat-resistant alloys, providing the minimum heat input in a part and regulating requirements to welding current value, time of existence of metal of weld micropool in molten state and its volume. 20 Ref., 2 Tables, 10 Figures.

Keywords: microplasma powder surfacing, narrow substrate, nickel heat-resistant alloy JS32, effective power of part heating, heat input, bead cross-section area, volume of weld micropool, surfacing efficiency, stress-strain state of welded joint

Received:                28.02.16
Published:               19.07.16


  1. Frolov, V.V., Vinokurov, V.A., Volchenko, V.N. et al. (1970) Theoretical principles of welding. Moscow: Vysshaya Shkola.
  2. Karasev, M.V., Grebenchuk,V.G., Rabotinsky, D.N. et al. (2009) Investigation of influence of semiautomatic gas mixture shielded welding conditions using rectifiers of VD-506DK type with flux-cored wire Power Bridge 60M on mechanical and viscous-plastic properties of deposited metal in welding of bridge structures. Svarka i Diagnostika, 4, 19–25.
  3. Shipilov, A.V., Konovalov, A.V., Brovko, V.V. et al. (2011) Control of welded joint structure in orbital TIG welding of industrial pipelines of compressor stations. Izvestiya VUZav,. Series Mashinostroenie, 6, 44–52.
  4. Paton, B.E., Gvozdetsky, V.S., Dudko, D.A. et al. (1979) Microplasma welding. Kiev: Naukova Dumka.
  5. Yarovytsyn, O.V. (2009) Microplasma powder surfacing of refractory nickel alloys containing 45-65 % of g?-phase: Syn. of Thesis for Cand. of Techn. Sci. Degree. Kiev: PWI.
  6. Gladky, P.V., Pereplyotchikov, E.F., Ryabtsev, I.A. (2007) Plasma surfacing. Kiev: Ekotekhnologiya.
  7. Yarovitsyn, A.V. (2015) Energy approach in analysis of microplasma powder surfacing modes. The Paton Welding J., 5/6, 14–21.
  8. Yushchenko, K.A., Yarovitsyn, A.V., Khrushchov, G.D. et al. (2015) Analysis of process of bead shaping in cladding on narrow substrate. Ibid., 9, 20–27.
  9. Melekhov, R.K., Pokhmursky, V.I. (2003) Structural materials of power equipment. Properties. Degradation. Kiev: Naukova Dumka.
  10. Yushchenko, K.A., Yarovitsyn, A.V., Yakovchuk, D.B. et al. (2013) Some techniques for reducing filler powder losses in microplasma cladding. The Paton Welding J., 9, 30–36.
  11. Boley, B., Weiner, J. (1964) Theory of thermal stresses. Moscow: Mir.
  12. Okerblom, N.O. (1948) Welding strains and stresses. Moscow; Leningrad: MAShGIZ.
  13. Talypov, G.B. (1973) Welding strains and stresses. Leningrad: Mashinostroenie.
  14. Nedoseka, A.Ya. (1998) Principles of calculation and diagnostics of welded structures. Kiev: Indprom.
  15. Budinovsky, S.A., Kablov, E.N., Muboyadzhan, S.S. (2011) Application of analytical model for determination of elastic stresses of multilayer system in solving of problems on development of high-temperature heat-resistant coatings of aircraft turbine blades. Vestnik MGTU im. N.E. Baumana, Series Mashinostroenie, 26–37.
  16. Golubovsky, E.R., Svetlov, I.L., Khvatsky, K.K. (2005) Principles of change of axial and azimuthal anisotropy of strength properties of heat-resistant nickel single crystals for GTE blades. -Kosmich. Tekhnika i Tekhnologiya, 26(10), 50–54.
  17. (2001) Melt pool size control in thin-walled and bulky parts via process maps. In: of 12th Solid Freeform Fabrication Symp. (Austin: Univ. of Texas), 432–440.
  18. Vasinonta, A., Beuth, J.L., Griffith, M. (2007) Process maps for predicting residual stress and melt pool size in the laser-based fabrication of thin-walled structures. Manufact. Sci. and Eng., 129(1), 101–109.
  19. Aggaransi, P., Beuth, J.L. (2007) Localized preheating approaches for reducing residual stress in additive manufacturing. Ibid., 709–720.
  20. Zhemanyuk, P.D., Petrik, I.A., Chigilejchik, S.L. (2015) Experience of introduction of the technology of reconditioning microplasma powder surfacing at repair of high-pressure turbine blades in batch production. The Paton Welding J., 8, 39–42.