TSU's PIS has improved the aluminum welding process

For a long time, modern welding equipment capable of generating complex-shaped current pulses has been outpacing theory. The lack of fundamental knowledge on how to control these pulses resulted in defects in the production of critical aluminum structures in practice.

Dmitry Sovetkin, a PhD student at TSU, under the scientific supervision of Professor Valery Yeltsov, Doctor of Technical Sciences, from the Department of Welding, Metal Forming and Related Processes at the Institute of Mechanical Engineering, Chemistry, and Energy, managed to find a solution by uncovering the thermal "secrets" of the compressed arc. His research for the first time provided a clear understanding of how controlled rectangular current pulses affect the weld pool and the electrode.

The practical embodiment of this scientific work consists of patented technologies that radically change the approach to welding aluminum structures. The scientists developed a unique non-consumable electrode with liquid cooling.

“Thanks to this design and precisely calibrated regimes with a predominance of reverse polarity pulses, it is now possible to use less powerful and more affordable equipment without compromising the strength and purity of the weld,” explains Dmitry Sovetkin.

The team proposed methods and tools that allow conventional TIG* machines to be used as power sources for plasma welding, making the transition to the new technology low-cost for enterprises.

Dmitry Sovetkin and his colleagues plan to deepen their research. To this end, a plasma welding laboratory has already been established and is operational at TSU.

“We see enormous potential in using our developments to control the structure of the deposited metal," the scientist shares his plans. "This is in demand, for example, in additive manufacturing, for 3D printing metal products with specified properties. I am confident that arc processes hold many more discoveries in store.”

Based on the materials of Dmitry Sovetkin's dissertation, 28 published works have been released, and 11 patents for inventions have been obtained. The research was conducted within the framework of TSU's Advanced Engineering School “Hybrid and Combined Technologies.”

*A TIG machine (Tungsten Inert Gas) is a tool for high-quality, precise, and clean welding of various metals. It is the "gold standard" for tasks where reliability and accuracy of the result are more important than speed.