TSU's PIS has improved the aluminum welding process

For a long time, modern welding machines capable of generating complex current pulses were ahead of the curve. A lack of fundamental knowledge about how to control these pulses resulted in defects in the production of critical aluminum structures.

TSU graduate student Dmitry Sovetkin, under the supervision of Valery Yeltsov, a professor in the Department of Welding, Material Forming, and Related Processes at the TSU Institute of Mechanical Engineering, Chemistry, and Power Engineering, succeeded in finding a solution by uncovering the thermal "secrets" of a constricted arc. His research provided the first clear understanding of how controlled rectangular current pulses affect the weld pool and electrode.

The practical implementation of this research has resulted in patented technologies that fundamentally change the approach to welding aluminum structures. The scientists have developed a unique non-consumable electrode with liquid cooling.

"Thanks to this design and precisely calibrated modes with predominantly reverse-polarity pulses, it is now possible to use less powerful and more affordable equipment without compromising the strength and cleanliness of the weld," explains Dmitry Sovetkin.

The team has proposed methods and tools that allow the use of conventional TIG machines as power sources for plasma welding, making the transition to the new technology cost-effective for companies.

Dmitry Sovetkin and his colleagues plan to further their research. A plasma welding laboratory has already been established and is operational at TSU for this purpose.

"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 and for 3D printing metal parts with specified properties. I am confident that arc processes hold many more discoveries."

Dmitry Sovetkin's dissertation has been used in 28 publications and 11 patents. The research was conducted as part of the Advanced Engineering School "Hybrid and Combined Technologies" at Tomsk State University.

*A TIG (Tungsten Inert Gas) welding machine is a tool for high-quality, precise, and clean welding of a wide variety of metals. It is the "gold standard" for applications where reliability and precision are paramount, not speed.