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EN
The aim of the research was to assess the adhesion of the powder flame sprayed coatings to the previously prepared substrate. The spraying tests were carried out using Rototec 51000 base powders which was Ni-Al-Mo alloys, then coated with an outer coating made of Rototec 19404, which is an alloy Fe-Cr-Co-Mo. The coatings were tested for adhesion in accordance with the PN-EN ISO 14916:2017 standard and also topography tests of sprayed coatings using scanning electron microscopy.
PL
Wzrastające wymagania przemysłu w zakresie jakości i ekonomiczności produkowanych wyrobów przyczyniają się do znacznego postępu w rozwoju różnych technologii spawalniczych, w tym także technologii cięcia. Prawdziwy postęp w technologiach cięcia dokonał się wraz z odkryciem w 1923 roku plazmy przez Irvinga Langumira, amerykańskiego fizykochemika. Wówczas plazma pierwszy raz wykorzystana została do cięcia termicznego w USA w firmie Linde w 1955 roku w celu cięcia metali nieżelaznych i odpornych na korozję. Obecnie cięcie plazmowe znajduje szerokie zastosowanie nie tylko w produkcji seryjnej, ale także w jednostkowej produkcji części konstrukcji i urządzeń, bądź w pracach warsztatowych. Cięcie plazmą swą popularność zawdzięcza wielu swoim zaletom, takim jak: duża wydajność, stosunkowo wysoka jakość ciętych powierzchni, możliwość przecinania materiałów o grubości do 150 mm oraz korzystne wskaźniki ekonomiczne [1-2].
PL
Wzrastające wymagania przemysłu w zakresie jakości i powtarzalności produkowanych wyrobów przyczyniają się do rozwoju różnych technologii spawalniczych, w tym również procesów cięcia. Wybór metody cięcia zależy od wymagań stawianych przez konstruktora danego elementu oraz możliwości technicznych, tj. rodzaju i grubości ciętego materiału, jakości cięcia, tolerancji wymiarowych, odchyłki prostopadłości, prędkości cięcia czy kształtu wycinanego elementu oraz od czynników ekonomicznych, do których zalicza się koszt inwestycji, koszt eksploatacji, efektywność procesu i stopień wykorzystania urządzenia [1-4, 8, 9]. Jedną z najczęściej wybieranych metod cięcia jest cięcie plazmowe.
PL
Cięcie jest operacją technologiczną, od której rozpoczyna się najczęściej cały proces produkcji elementów maszyn, urządzeń i konstrukcji metalowych. Panujący w przemyśle postęp technologiczny dyktuje coraz wyższe standardy dotyczące ich wytwarzania. Od technologii cięcia wymaga się nie tylko wysokiej dokładności, wąskiej szczeliny cięcia i niskiego wpływu cieplnego na cięty przedmiot, ale także jak najwyższej ekonomiczności procesu (niskie zużycie energii).
PL
Rozwój technologii cięcia sprawił, że w coraz szerszym zakresie cięcie plazmowe staje się konkurencyjne do innych technologii cięcia termicznego.
6
Content available remote Cost comparison between oxyfuel and plasma cutting low alloy steel
EN
Purpose of this paper: This paper presents a comparison of the oxyfuel flame cutting and plasma cutting in economic terms. The cutting method you can choose depends on the type, thickness and amount of metal you need to cut as well as the cut quality you require. The cost estimation is also critical. In order to obtain maximum of technical and economical efficiency, in these cases, very important is to estimate the production cost and the production rates. Knowledge of investment and operating cost represents a base for investment in cutting machine. For different cutting machines typical investment costs and operating costs depend from the power of the cutting machine and important. To determine the cost of cutting 1 m it should be specify the type of cutting material, cut quality and used parameters. In this paper economic analysis of the cutting processes has been performed for low alloy steels with thicknesses of 2, 5, 10, 15, 25 and 50 mm. In this economic analysis were calculated the direct costs (electric energy, gases, depreciation and consumables), without the labour cost. The analysis shows that the cheapest cutting process for 10-15 mm thick is plasma cutting, for a thicker plates more economical process is the oxyfuel flame cutting. Plasma cutting provides a good balance in terms of capital costs and a optimal mix of cut quality, productivity and operating cost. It offers a significant thickness range and material flexibility and provides the highest cutting speed. Design/methodology/approach: Different measures of cost may be appropriate, depending upon the context in which the comparison is being made. In this paper used the most common measures (cost per unit time, cost per unit length) Findings: In this economic analysis were calculated the direct costs (electric energy, gases, depreciation and consumables), without the labour cost. Cost estimation of cutting methods and assessment of the most cost effective process for a given type of parts manufacture is quite an involve process. It depends on many factors related with the quality that must be obtained. Research limitations/implications: All cutting technologies have stable long term industrial application and differ distinctively by technological parameters, economics and quality of cut edges. Knowledge of a cutting system’s investment and operating costs should form the basis for evaluating its profitability. The investment and operating cost must be justified according to economic criteria with corresponding financial advantages. Practical implications: In addition to the technical aspect, which has a significant impact on the choice of cutting technology is a very important to know the economic aspect. To see the competitiveness of the method, it is important to know the actual cost of cutting 1 meter in length. Comprehensive analysis of the technical and economic aspects of cutting technology allows to avoid wrong decisions. Originality/value: In this paper economic analysis of the cutting processes has been performed for low alloy steels with thicknesses of 2, 5, 10, 15, 25 and 50 mm. In this economic analysis calculated the direct costs (electric energy, gases, depreciation and consumables), without the labour cost.
PL
Jednym z podstawowych kryteriów oceny jakości napawanych modułów ochronnych pancerza jest ich odporność balistyczna oceniana zgodnie z normami światowymi (np.: MIL-A-12560H, MIL-DTL-46100E, STANAG 4164, STANAG 4190, TOP-2-2-713, PN-EN 1523:2000, DI-SAFT-81132). Jednym z ważniejszych parametrów decydujących o odporności balistycznej jest przyczepność napawanej warstwy do podłoża.
PL
Lotnicze silniki odrzutowe pracują w warunkach losowo zmiennych obciążeń dynamicznych w wysokich temperaturach i jednoczesnym oddziaływaniu zjawisk zużycia ściernego i erozji. Z uwagi na tak szczególne warunki pracy lotniczych silników odrzutowych, bez względu na rzeczywisty stan zużycia silnika, zgodnie z odpowiednimi przepisami Producenta, silniki te muszą być poddawane okresowym przeglądom i remontom. Bardzo wysoki koszt części, a jednocześnie coraz wyższy poziom jakości nowoczesnych spawalniczych technologii naprawczych sprawia, że światowy przemysł lotniczy coraz powszechniej stosuje do naprawy zużytych części silników lotniczych technologie spawania i napawania. Celem pracy naprawa uchwytów klapy dużej biernej odrzutowego silnika lotniczego samolotu MIG 29. Klapy duże bierne wykonane są ze stopu tytanu WT-20. Praca w wysokich temperaturach przy losowo zmiennych obciążeniach dynamicznych i jednoczesnym oddziaływaniu tarcia metal - metal sprawia, że następuje intensywne zużycie ścierne uchwytów mocujących. Badania procesu napawania i stopowania prowadzono na stanowisku wyposażonym w laser HPDL oraz na zautomatyzowanym stanowisku plazmowym, materiałami dodatkowymi zapewniającymi zwiększoną odporność na zużycie ścierne typu metal-metal, w stosunku do materiału podłoża. Wykonano również badania odporności na zużycie ścierne typu metal-metal zgodnie z normą ASTM G99-95a. Wyniki badań tribologicznych wykazały, że warstwa napawana laserowo z dodatkiem proszku 50%Ti-50%WC spełnia najlepsze warunki i jest prawie 124 razy bardziej odporna na zużycie ścierne typu metal-metal niż powierzchnia nieutwardzona.
EN
Aircraft jet engine parts are working in very complex environment under very strong mechanical dynamic loads, erosion and friction wear and high temperatures. Due to very strict rules of maintenance of jet engines all parts are subjected precise quality control and defects are detected two options are used; worn parts are scraped and replaced by new one or repair process is employed. Because o' very high cost of jet engines spare parts and high quality repair process many jet engines maintenance companies decide to repair worn parts by application of modern laser welding and cladding technology. The aim of this study was regeneration of the RD-33 engine jet flaps used m MlG 29 fighters. Examined jet flaps are a welded constructions of forged WT-20 titanium alloy elements. Work under rugged conditions such as elevated temperatures, corrosion environment, variable load and friction of cooperating metal parts leads to intensive wear of reinforcing ribs and handles. Research on the development of technological condition of the jet flaps regeneration was carried out on a stand equipped with high-power diode laser HPDL Rofin Sinar DL020 and plasma 2001 DC GAP Detailed studies showed that regeneration by welding requires additional materials providing improved wear resistance of metal-metal type, relative to the base material - WT-20 titanium alloy. In order to evaluate the abrasive wear resistance, regenerated parts were tested according to ASTM G 99-95a "Standard test method for wear testing with a Pin-on-Disk Apparatus”. It was found that abrasive wear resistance of 50%Ti+50%WC cermet deposits is significantly higher compared to WT-20 titanium alloy base material.
9
Content available remote Technologia naprawy uchwytów klapy dużej biernej silnika odrzutowego RD-33
PL
Badania uszkodzeń uchwytów klapy dużej biernej silnika wykazały, że naprawa tych elementów wymaga opracowania warunków technologicznych napawania automatycznego plazmowego PTA oraz napawania laserowego HPDL materiałami dodatkowymi zapewniającymi zwiększoną odporność na zużycie ścierne metal-metal, w stosunku do materiału podłoża. Wstępne próby napawania plazmowego PTA oraz napawania laserowego HPDL wykazały, że można uzyskać napoiny wysokiej jakości. Przez odpowiedni dobór parametrów napawania możliwe jest sterowanie wymiarami napoin oraz udziałem materiału podłoża w napoinie. Wykonano również badania odporności na zużycie ścierne połączenia metal-metal zgodnie z normą ASTM G99. Wyniki badań tribologicznych wykazały, że warstwa napawana laserowo z dodatkiem proszku 50%Ti-50%WC spełnia wszystkie warunki i jest prawie 124 razy bardziej odporna na zużycie ścierne typu metal-metal niż powierzchnia nieutwardzona.
EN
Tests of handles of large passive flap, showed that the repair of these elements requires the development of technological conditions of automatic plasma PTA surfacing and HDPL laser surfacing with filler materials ensuring increase resistance to wear of metal-metal, relative to the substrate material. Trial attempts of PTA plasma surfacing and HPDL laser surfacing showed that there is a range of parameters to obtain high-quality padding welds. By appropriate parameters it is possible to control the padding weld dimensions and the participation of substrate material in the padding weld. There is also carried out the wear resistance of metal-metal in accordance with ASTM G99 tests. Tribological test results showed that the layer made with the use of laser and powder, 50% Ti 50% WC meets the best conditions and is almost 124 times more resistant to metal-metal abrasive wear than the unhardened surface.
10
Content available remote Technology of laser repair welding of nickel superalloy inner flaps of jet engine
EN
Purpose: of this paper: work out laser welding repair technology of cracked MIG 29 jet engine inner flaps made of cast nickel superalloy ŻS-3DK(ЖС-3ДК, Russian designation). Design/methodology/approach: The study were based on the analysis of laser HPDL powder INCONEL 625 welding of nickel superalloy using wide range of welding parameters to provide highest quality repair welds. Findings: Study of automatic welding technologies GTA, PTA and laser HPDL has shown that just laser welding can provide high quality repair welds. In order to establish the properties of welded joints repair cracks in the inner flap HPDL laser, studied the hardness, mechanical properties and erosive wear resistance. Research limitations/implications: It was found that only laser HPDL welding can provide high quality repair welds. Practical implications: The technology can be applied for repair cracked MIG 29 jet engine inner flaps. Originality/value: Repairing cracked MIG 29 jet engine inner flaps.
11
Content available remote Laser repair hardfacing of titanium alloy turbine
EN
Purpose: of this paper: work out repair technology of worn abutments of aircraft jet engine blades forged of titanium alloy WT3-1. Design/methodology/approach: The study were based on the analysis of laser HPDL powder surfacing of titanium alloy plates using wide range chemical composition consumables of titanium alloys and mixtures of pure titanium and spherical powder of WC indicated that very hard and highest quality deposits are provided by powder mixture of 40-50%Ti+60-50%WC. Findings: It was found that it is possible to achieve high quality deposits, free of any defects. HPDL technology can be used to repair worn turbine blade. Research limitations/implications: It was found that it is possible to repair the worn areas abutments of blades of zero compression stage of aircraft engine turbine by HPDL laser surfacing with using composite powder mixture of 50%Ti+50%WC as an additional material. Practical implications: The technology can be applied for repair worn abutments of aircraft jet engine blades. Originality/value: Repairing worn abutments of aircraft jet engine blades.
PL
Przedstawiono próby napawania laserowego na podłożu ze stali S355NL drutem proszkowym cermetalowym zawierającym w osnowie stopu niklu węgliki wolframu WC. Określono wpływ podstawowych parametrów napawania: mocy wiązki laserowej, prędkości napawania oraz prędkości podawania drutu na jakość, kształt oraz wymiary geometryczne napoin.
EN
The influence of technological conditions of laser surfacing using cermetal cored wire EnDoTec DO*11 on the quality, shape and size and dilution of the deposits surfaced on the substrate of S355NL steel has been described.
PL
Przeprowadzono próby napawania laserowego krążków ze stali narzędziowej do pracy na gorąco X37CrMoV5-1 z jednoczesnym podawaniem drutu litego ze stali austenitycznej CastoMag 45500 i proszku ceramicznego MetaCeram 28060 do jeziorka spawalniczego napoiny. Określono wpływ podstawowych parametrów napawania: mocy wiązki laserowej, prędkości napawania, prędkości podawania drutu oraz natężenia podawania proszku na jakość, kształt, oraz wymiary geometryczne napoin.
EN
Results of the study of the technology of laser surfacing of X37CrMoV5-1 hot work tool steel during simultaneous feeding of solid wire CastoMag 45500 and powder MetaCeram 28060 into the weld pool are presented. Results of the surfacing parameters on quality and geometry are given.
14
Content available remote Study of laser welding of copper sheets
EN
Purpose: Purpose of this research is to study laser autogeneous welding process of short seam beads and fillet welds of lap joints of oxygen-free copper sheets 1.0 [mm] thick. On the bases of results of quality assessment it was proved that high power diode laser (HPDL) welded lap joints of copper sheet provide mechanical properties on the level of parent material. Design/methodology/approach: Short seam beads and fillet welds of lap joints of oxygen-free copper sheets 1,0 [mm] thick were tested, to establish the optimum parameters of high power diode laser autogeneous welding process. Findings: It was shown that there is very narrow range of optimum HPDL autogeneous welding parameters of short seam beads and fillet welds of lap joints of oxygen-free copper sheets 1,0 [mm] parameters. It was proved that high power diode laser (HPDL) autogeneous welded lap joints provide mechanical properties on the level of parent material. Practical implications: It is possible to produce high quality short seam bead and fillet weld lap joints of oxygen-free copper sheets 1.0 [mm] thick. It was proved that high power diode laser (HPDL) autogeneous welded lap joints provide mechanical properties on the level of parent material. Originality/value: The optimum HPDL autogeneous welding parameters of short seam beads and fillet welds of lap joints of oxygen-free copper sheets 1.0 [mm] parameters makes possible to produce high quality laser autogeneous welded lap joints of copper sheets 1.0 [mm] thick.
15
Content available remote Abrasive and erosive wear resistance of GMA metal cored wire cermetal deposits
EN
Purpose: Purpose of these researches was to determine influence of GMA metal cored wire surfacing parameters on the abrasive and erosive wear resistance of the one layer and three layer weave bead cermetal deposits. Design/methodology/approach: One layer and three layer wave bead deposits were GMA surfaced using metal cored wire (nickel based - 54%WC) 1.6 [mm] dia. To determine quality of deposits Visual Inspection, MT examinations, hardness HRC and HV10 measurements on the ground surface of deposits, macrostructure and microstructure observations, abrasive and erosion wear resistance tests were done. Findings: Hardness of deposits tested is in the range from 453-517 HV 10(44.5-47.9 HRC) and is a function of the value of heat input of surfacing. WC carbides population density, size and distribution in nickel alloy matrix of deposits tested is a function of GMA heat input of surfacing. Low heat input of surfacing insures uniform distribution of WC carbides on the cross section of deposits. The low heat input GMA surfaced weave bead deposits provide 10 times higher abrasion wear resistance and 4.2 times higher erosion wear resistance than HARDOX 400 steel plate. Research limitations/implications: Results of this paper is to increase quality of GMA cermetal deposits. Originality/value: Hardness of deposits can not be treated as the abrasion and erosion wear resistance indicator.
16
Content available remote Abrasive wear resistance of robotized GMA surfaced cermetal deposits
EN
Purpose: of this paper: Study of abrasive wear resistance of robotized GMA surfaced cermetal deposits. The one-, two-and three layers stringer bead and weave bead deposits were surfaced by a metal-cored wire. Design/methodology/approach: The study were based on the analysis of deposits dilution, structure, measurements of hardness and microhardness, determination of WC carbide morphology and abrasive wear resistance type metal-ceramic according to ASTM G65. Findings: It was found that robotized GMA surfacing process with EnDOtec DO*11 wire of diameter 1,6 [mm], with oscillation of the welding torch, can be applied for producing high quality of deposits in a wide range of surfacing parameters especially heat input. The abrasive wear resistance of stringer bead deposits is significantly higher compared with weave bead deposits. The weave bead deposits are free of transverse cracks, contrary to stringer beads. This phenomenon can be explained by different thermal stresses in the deposits. Research limitations/implications: It was found that further investigations and detailed studies are required to identify the mechanism of deposit shaping, especially the control of dilution, shape of fusion zone and penetration depth, depending on parameters of surfacing and the trajectory and parameters of oscillation of the surfacing GMA torch. Practical implications: The technology can be applied for wear plates manufacturing . Originality/value: Improve of the wear resistance of wear plates.
PL
Przedstawiono wyniki badań wpływu energii liniowej napawania GMA i temperatury podgrzewania wstępnego na jakość i kształt ściegów prostych napoin jednowarstwowych wykonanych metodą GMA na podłożu ze stali S355NL drutem proszkowym cermetalowym Ni-Wc. Wykazano, że przez odpowiedni dobór warunków technologicznych napawania GMA istnieje możliwość wykonania wysokiej jakości napoin bez pęknięć poprzecznych wywołanych naprężeniami spawalniczymi.
EN
The results of examination concerned influence of linear energy in padding GMA and preliminary temperature on quality and shape of padding weld are presented. Weld are made on base from S355NL using wire Ni-WC.
18
Content available remote Robotized GMA surfacing of cermetalic layers
EN
Purpose: Purpose of these researches was to investigate of influence of heat input in robotized surfacing on quality and properties of cermetalic layers. Design/methodology/approach: The quality of single and multilayer, stringer and weave beads was assessed by abrasion resistance tests according to ASTMG65 standard, erosion resistance tests according to G76 standard, metallographic examinations and hardness tests. Findings: Due to the fact that the it was used robotized surfacing stand, the analysis of properties of the deposits was performed for single and multilayer, stringer and weave beads. Research limitations/implications: For complete information about tested wear plates it is needed to compare theirs properties with others presented technologies of wear plates producing. Practical implications: Results of this paper is to optimal range of parameters of surfacing of single and multilayer, stringer and weave beads of cermetalic layers. Originality/value: The researches (hardness tests, abrasion and erosion resistance tests) were provided for surfacing of single and multilayer, stringer and weave beads, and the results were compared. The influence of heat input on layers properties and theirs structure was defined.
19
Content available remote Robotized GMA surfacing of cermetal deposits
EN
Purpose: Purpose of this paper: Study of robotized GMA metal-cored wire surfacing of one-, two- and three layers stringer bead and weave bead deposits has been carried out. Design/methodology/approach: The dilution of deposits, structure, hardness, WC carbide morphology and abrasive wear resistance type metal-ceramic as per ASTM G65, was determined. Findings: It was shown that the abrasive wear resistance of stringer bead deposits is higher than weave bead deposits. Study of robotized GMA surfacing process with EnDOtec DO*11 wire of diameter 1.6 [mm], applying weaving (oscillation) technique of surfacing, showed that it is possible to produce high quality of deposits in a wide range of surfacing parameters (heat input). Contrary to stringer bead deposits, weave bead deposits are transverse cracks free which can be caused by thermal stresses in the deposits. Research limitations/implications: The mechanism of deposit formation (shaping), especially the control of dilution, shape of fusion zone and penetration depth, depending on parameters of surfacing and the trajectory and parameters of oscillation of the surfacing torch demands further investigations and detailed studies. Practical implications: The technology can be applied for wear plates manufacturing. Originality/value: Improve of the wear resistance of wear plates.
PL
Przedstawiono wyniki badań wpływu podstawowych parametrów napawania metodą GMA drutem litym martenzytycznym chromowym o średnicy 1,2 mm na jakość i kształt ściegów prostych napoin. Określono również wpływ techniki napawania (kierunku i kąta pochylenia uchwytu GMA) na udział materiału podłoża w napoinie.
EN
The results of investigation on the influence of the main parameters of GMA surfacing with the use of martensitic chromium solid wire, 1,2 mm in dia., on the quality and shape of overlay string beads have been presented. The effect of surfacing technique (direction and inclination angle of GMA torch) on the fraction of base metal in weld overlay has been also determined.
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