Welding

Welding

The welding process is performed according to the following standards:

CPW 24,
YC03H,
AWS D17,
P8K-AG1, P8K-AG2,

or according to the requirements of the clients.

WELDING: ELECTRIC RESISTANCE AND TIG WELDING

Most present welding procedure of turbojet engine parts is TIG welding procedure, i.e. manual and automatic circumferential and longitudinal welding. Materials being welded by this procedure are mostly as follows: high-alloyed and fireproof steels, nickel, titanium and aluminum alloys. It should be pointed out that we have equipment for argon shielded welding of titanium and titanium alloys with mastered technology of welding these alloys.

We complete welding processes as follows:

  1. TIG-welding process with additional material;
  2. TIG-welding process without any additional material;
  3. Electric resistance seam welding;
  4. Electric resistance spot welding

TIG welding chamber 100% protective atmosphere,

Workspace dimensions: 1800x1800x920 mm,

Welding of parts up to 1250 mm in length,

Min. welding diameter: 102 mm

Manual TIG welding of the front section of the turbojet engine combustion chamber  using a Muller SynhroWave welding machine

Sciaky M300STI                Sciaky P200STI

Round seam welding:          Spot welding:

  • 3 phases,
  • 620 KVA,
  • For welding sheets from 0.5 to 3 mm thickness

PW Resistance Welding Products Inc. electric resistance welding machine for thin sheets.

  • Thickness of welded sheets below 0.5 mm
  • Possibility of seam and spot welding

      

  • Microplasma welding

For manual or automatic precision joining of metal parts of small thickness, from 0.05 to 1.0 mm (stainless steels, Inconel, titanium, alloys based on silver and gold)

Primary power supply

 

·        Supply voltage (V)

230-400-440 V

(50-60 Hz, three-phase

Cos  Ф

0.91

Max. primary current

6 A (below 400 V)

Secondary power supply:

 

·        Continuous and  pulse plasma

Min. 80 m A – max. 50 A at 100%

·        Continuous and  pulse TIG

Min. 0.8-  max. 50 A at 60%

·        Open circuit voltage

106 V

·        Pulse frequency

From 1Hz to 10 kHz

ELECTRON BEAM WELDING (EBW)

Primary application of EBW procedure is welding of hard-fusible and hard-weldable materials (titanium and titanium alloys, nickel superalloys, tool and highalloyed steels, tungsten, vanadium, etc.), which cannot be welded by any other welding procedures.
In addition to wide range of materials that can be welded, the main advantages of the procedure are:

  • welding without filler metal in one pass, so that weld is of the same material as the one being welded ;
  •  welding is performed in vacuum, which enables full protection of melted metal ;
  • electron beam, as a source of high density of energy enables minimum deformation of welded joints ;
  • there is no difference (or they are minimum) in mechanical properties of welded joints in comparison with those of parent metal.

EBW procedure enables welding part locations that are hard to access, as well as welding of more layers in one pass.


Messer Griesheim K100/G 150 K - CNC machine for electron beam welding

For reasons of small electron beam area, high welding precision, and high quality of welds is obtainable.

Data on device:

 

Manufacturer: Messer Griesheim
Model: K100/G 150 K - CNC
Machine features: ◦ gun power 15 KW, i.e. gun voltage 150 KV
◦ beam power intensity 100 mA
◦ chamber vacuum 5.10-4 mbar (high vacuum)
◦ gun vacuum 10-2 mbar
Data on vacuum chamber: ◦ length (X): 2700 mm
◦ width (Y): 2000 mm
◦ height (Z): 2100 mm
Table movement: ◦ X-direction: 1325 mm
◦ Y-direction: 975 mm

Weld on INCONEL 718 superalloy obtained by welding on Messer Griesheim K100/G 150 K - CNC

For example, the following turbojet engine parts are welded by use of this procedure: reheat chamber ring (NIMONIC 263 material), reheat chamber, inner ring with II stage turbine rotor, etc.

EBW CNC five-axis device Messer Griesheim K100/G 150 K:

Electron beam  power: 15 kW @ 150 kV

Working chamber: 12 m3

Workpiece: Ф800 x 1200 mm

Vacuum in the working chamber: 5x10-4 mbar

Welding speed: 100 mm/s

Accuracy: ± 0.05 mm

As an example of using this welding procedure is the production of parts of turbojet engines: the ring of the combustion chamber (material NIMONIC 263), the inner ring with the second stage of the turbine rotor, various shafts, gears, air inlet nose caps, etc.

Welded joint with Messer Griesheim K100/G 150 K - CNC at welding super alloy INCONEL 718

Advantages of electron beam welding: ability to maintain narrow tolerances, repeatability of welding parameters, low level of heat input, minimal distortion, integrity of high strength welds (clean, strong and consistent), joining of the same or different metals without filler, cost-effectiveness with meeting strict design requirements etc.

Orao

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