Ganushchak O. Development of a technology for butt plasma-arc multi-pass welding of the titanium-steel bimetal with application of barrier coatings

Українська версія

Thesis for the degree of Doctor of Philosophy (PhD)

State registration number

0825U000370

Thesis Registration Form

0825U000370.pdf

Applicant for

Oleg V. Ganushchak

Specialization

132 - Матеріалознавство

Date of defense

12-02-2025

Specialized Academic Board

PhD 7410

E.O. Paton Electric Welding Institute (PWI)

Essay

This dissertation is dedicated to studying the metallurgical features of plasma-arc multi-pass welding processes for titanium-steel bimetals using barrier interlayers to minimize or completely eliminate intermetallic phases (IMPs) that typically form during the interaction of titanium and steel under certain temperature conditions. The investigation of these metallurgical features enables the development of technologies for producing welded joints of acceptable quality, suitable for chemical industries and main pipelines. To enhance operational lifespan, pipes for such pipelines are manufactured using steel lined with a layer of titanium or titanium alloy on the inner surface. The presence of a titanium layer and the stringent requirements for the strength and corrosion resistance of the welded joints pose challenges in choosing appropriate welding methods. There is an urgent need for the development of specific technological techniques, welding methods, and a technology for joining steel sheets lined with titanium, which would ensure the production of pipe products of the required quality at relatively low costs. Object of research – Plasma and arc welding processes of structural low-carbon steel clad with a layer of titanium using barrier coatings. Subject of research – Formation of a butt-welded joint of titanium-steel bimetal during multi-pass welding. The purpose of the work – To investigate the efficiency of applying barrier coatings made of various materials to titanium and steel using plasma-arc surfacing and spraying methods to minimize the formation of intermetallic phases during butt welding of steel sheets lined with titanium. The ultimate goal is to develop a technology for producing such butt joints. The scientific novelty of the research includes the following provisions: 1. For the first time, the regularities of the influence of the value of the linear energy E on the thickness of the transition zone formed by the interaction of the steel melt with titanium in the processes of plasma and arc surfacing of steel on titanium, and including intermetallic phases Ti-Fe, namely, at a value of E in the range of 45-60 J/mm, this value is 10-60 μm, and with an increase in the value of E to 60-100 J/mm, it reaches 450 μm and more with the formation of a significant number of microcracks and other defects. 2. The understanding of the peculiarities of structure formation during the metallurgical interaction of vanadium with steel in the processes of plasma and arc surfacing of vanadium coating on steel and steel on this coating was further developed, it was found that in the transition zone between the deposited vanadium coating and steel an intermetallic layer of variable concentration (40-75 wt.% V and 60-25 wt.% Fe) and increased hardness (up to 5520 MPa) is formed, which leads to crack formation. 3. The idea of the peculiarities of metallurgical interaction of copper alloy melt with titanium and steel was further developed, namely, the conditions for applying a barrier coating of CuSi3Mn1 alloy to a titanium plate were established, under which the mutual diffusion of elements at the “titanium-CuSi3Mn1-steel” interface does not lead to the formation of brittle phases and crack formation. 4. For the first time, the features of the metallurgical interaction at the interface "titanium - plasma sprayed steel coating" during plasma-arc welding of a steel wire on this coating were revealed, namely, the conditions for minimizing its thickness (at least 400 μm) and the value of the linear energy of welding on this coating (up to 200–250 J/mm), in which a defect-free transition zone is formed between the sprayed coating and titanium. 5. It was established for the first time that as a result of heating with plasma and arc welding sources during the filling of the development of the titanium-steel butt joint in the process of multi-pass welding up to 900–1300⁰С in the contact zone of titanium and steel in the solid phase, a defect-free transition zone with a thickness of 1 μm to 10 μm, in which a mixture of intermetallics with a microhardness of HV 600–800 and an integral chemical composition corresponding to the formula Ti2Fe is formed when the temperature is further increased to 1430⁰С.

Thesis supervisor

Volodymyr M. Korzhyk

Official opponents

Oleksii A. Slyvinskyi
Oleksandr P. Shatrava

Reviewers

Anatoliy V. Zavdoveev
Artemy V. Bernatskyi

Research papers

Comparing features in metallurgical interaction when applying different techniques of arc and plasma surfacing of steel wire on titanium / V. Korzhyk, V. Khaskin, A. Grynyuk, O. Ganushchak, S. Peleshenko, O. Konoreva, O. Demianov, V. Shcheretskiy, N. Fialko. Eastern-European Journal of Enterprise Technologies. 2021. Vol. 4, No. 12(112). P. 6–17.

Analyzing metallurgical interaction during arc surfacing of barrier layers on titanium to prevent the formation of intermetallics in titanium-steel compounds / V. Korzhyk, V. Khaskin, A. Grynyuk, O. Ganushchak, V. Shcheretskiy, S. Peleshenko, O. Konoreva, O. Demianov, N. Fialko V. Kvasnytskyi. Eastern-European Journal of Enterprise Technologies. 2021. Vol. 5, No. 12(113). P. 69–82.

Features of structure formation when surfacing steel (iron) on titanium with plasma sprayed coatings in the technology of obtaining butt joint of bimetallic plates "titanium – steel" / V. Korzhyk, V. Khaskin, O. Ganushchak, D. Strohonov, Y. Illiashenko, N. Fialko, C. Guo, A. Grynyuk, S. Peleshenko, A. Aloshyn. Eastern-European Journal of Enterprise Technologies. 2023. Vol. 2, No. 12(122). P. 6–16.

Preparing permanent joints of titanium alloys with steel (A review) / V. Korzhyk, V. Khaskin, V. Kvasnytskyi, O. Ganushchak, I. Hos, S. Peleshenko, O. Demianov, O. Konoreva, N. Fialko. Materials Science. 2023. Vol. 59, No. 2. P. 129–137, 5-16.

Features of intermetallic formation in the solid phase on a steel–titanium bimetal interface under the conditions of arc welding / V. Korzhyk, Yu. Zhang, V. Khaskin, O. Ganushchak, V. Kostin, V. Kvasnytskyi, A. Perepichay, A. Grynyuk. Metals. 2023. Vol. 13. P. 1338.

Підвищення ефективності роботизованого виготовлення сталевих фермових зварних конструкцій / В.М. Коржик, А.А. Гринюк, В.Ю. Хаскін, Є.В. Ілляшенко, І.М. Клочков, О.В. Ганущак, Yu Xuefen, Li. Huang. Автоматичне зварювання. 2021. № 5. C. 15–20.

Імпульсно-плазмове модифікування поверхні сталевих штампів гарячої витяжки виробів із титанового сплаву / Ю.М. Тюрін, О.В. Колісніченко, В.М. Коржик, І.Д. Гос, О.В. Ганущак, Jin Ying, Zhong Fengping / Автоматичне зварювання. 2021. №5, C. 56–61.

Ефективність процесу плазмово-дугової сферодизації струмопровідного титанового дроту / В.М. Коржик, Д.В. Строгонов, О.М. Бурлаченко, А.Ю. Тунік, О.В. Ганущак, О.П. Грищенко. Сучасна електрометалургія. 2023. № 1. C. 1–9.

Установка нового покоління для плазмоводугового нанесення покриттів і розпилення струмопровідних дротових матеріалів / В.М. Коржик, Д.В. Строгонов, О.М. Бурлаченко, О.В. Ганущак, О.М. Войтенко. Сучасна електрометалургія. 2023. № 3. C. 19–27.

The technology of plasma-arc atomization of current-carrying solid wires for titanium powder production / D. Strohonov, O. Tereshchenko, O. Burlachenko, V. Korzhyk, O. Ganushchak, O. Konoreva. Sciences of Europe. 2024. No. 147. P. 116–119.

Підвищення ефективності роботизованого виготовлення сталевих фермових зварних конструкцій / В. Коржик, А. Гринюк, В. Хаскін, Є. Ілляшенко, І. Клочков, О. Ганущак, Ю. Сюефен, Л. Хуан. Сучасні технології з’єднання матеріалів: збірка тез пленарних та стендових доповідей міжнародної конференції (м. Київ, 31 травня - 2 червня 2021 р.). Київ, 2021. С. 25.

Investigation of the formation of a transition layer of steel on the surface of titanium in obtaining joint "titanium-steel" / V. Korzhyk, O. Demianov, A. Grynyuk, O. Ganushchak, V. Shevchenko, O. Sitko, V. Popov, T. Oleinichenko. The 6th International scientific and practical conference – Results of modern scientific research and development (Madrid, August 22-24, 2021). Barca Academy Publishing, Madrid, Spain, 2021. Р. 117–119.

Plasmatron development for plasma-arc spraying of a fusible wire-anode / O. Voitenko, V. Korzhyk, O. Demianov, V. Shcheretskyi, Ye. Illiashenko, O. Ganushchak, D. Strohonov, І. Gos. The 3rd International scientific and practical conference "Modern scientific research: achievements, innovations and development prospects" (Berlin, August 29-31, 2021). MDPC Publishing, Berlin, Germany, 2021. Р. 77–79.

The electrodes of hybrid plasmatron for plasma-gmaw / V. Korzhyk, V. Khaskin, O. Babych, A. Grynyuk, O. Ganushchak, V. Shevchenko, S. Peleshenko, O. Voitenko. The 11th International scientific and practical conference "European scientific discussions" (Rome, September 12-14, 2021). Potere della ragione Editore, Rome, Italy, 2021. Р. 57–60.

Optimization of laser and hybrid laser-gmaw welding of high-strength steels by strength characteristics / V. Korzhyk, V. Khaskin, A. Grynyuk, O. Babych, Ye. Illiashenko, T. Oleinychenko, O. Ganushchak Ye. Popov. The 11th International scientific and practical conference "European scientific discussions" (Rome, September 12-14, 2021). Potere della ragione Editore, Rome, Italy, 2021. Р. 61–63.

Application of laser recovery surface / V.Korzhyk, V. Khaskin, A. Grynyuk, S. Peleshenko, O. Babych Ye. Illiashenko, T. Oleinychenko, O. Ganushchak, Ye. Popov. The 3rd International scientific and practical conference "Topical issues of modern science, society and education" (Kharkiv, October 3-5, 2021). SPC "Sciconf.com.ua", Kharkiv, Ukraine, 2021. P. 229–232.

Application of laser recovery surface Comparison of features of formation of structure of a transition layer "Steel-Titanium" at plasma-arc spraying and surfacing of a steel layer / V. Korzhyk, Y. Illiashenko, O. Ganushchak. Abstracts of IV international scientific and practical conference "Problems of practice, science and ways to solve them" (Milan, October 11 – 13, 2021). Milan, Italy, 2021. P. 151–152.

Аналізування ефективності технологічних прийомів отримання стикових з’єднань біметалевих пластин «титан–сталь» із застосуванням методів зварювання плавленням / В. М. Коржик, А. А. Гринюк, В. Ю. Хаскін, О. В. Ганущак Є. В. Ільяшенко, В. В. Квасницький, С. І. Пелешенко. Зварювання та споріднені технології: перспективи розвитку: тези доповідей V Міжнародної науково-технічної конференції (Краматорськ, 19–20 жовтень 2021 р.). Краматорськ, Україна, 2021. C. 37–40.

Achievements of the E.O. Paton electric welding institute in the field of welding thin sheet alloys for automotive applications / V. Korzhyk, V. Khaskin, A. Grynyuk, S. Peleshenko, Ye. Illiashenko V., Shcheretskiy, O. Ganushchak. The 5th International scientific and practical conference "Modern scientific research: achievements, innovations and development prospects" (Berlin, October 24-26, 2021) MDPC Publishing, Berlin, Germany, 2021. Р. 167–174.

Application of laser welding technologies in the automotive industry (review) / V. Korzhyk, V. Khaskin, A. Grynyuk, V. Shcheretskiy, S. Peleshenko, O. Ganushchak, V. Shevchenko. The 5th International scientific and practical conference "Modern scientific research: achievements, innovations and development prospects" (Berlin, October 24-26, 2021). MDPC Publishing, Berlin, Germany, 2021. Р. 175–182.

Overview of some perspective technical solutions on laser brazing with filler wires / V. Korzhyk, V. Khaskin, S. Peleshenko, A. Grynyuk, I. Hos, O. Ganushchak, O. Babych, D. Strogonov. The 3rd International scientific and practical conference "Innovations and prospects of world science" (Vancouver, November 4-6, 2021). Perfect Publishing, Vancouver, Canada, 2021. Р. 242–253.

Investigation of the features of the volt-ampere characteristic of the plasma arc of multipolar asymmetric current / V. Korzhyk, A. Grynyuk, V. Khaskin, S. Peleshenko, A. Aloshyn, O. Ganushchak. The 3rd International scientific and practical conference "Modern science: innovations and prospects" (Stockholm, December 5-7, 2021). SSPG Publish, Stockholm, Sweden, 2021. Р. 242–253.

Prevention of formation of intermetallides in welded joints "titanium-steel" by arc surface of barrier layers / V. Korzhyk, V. Khaskin, O. Ganushchak, Yu. Zhang, A. Grynyuk, S. Peleshenko, Ye. Illyashenko. The 35 th International scientific and practical conference "Modern Science" (Great Britain, 16-17 June, 2022). Nika Publishing, Leeds, Great Britain, 2022. Р. 87–95.

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