E.O. Paton Electric Welding Institute

The review is concerned with the current status of research on the use of plasma jets for the modification of surface properties of metalware, as well as of investigations of doping and mass transfer of elements. The effect of thermal plasma parameters on the efficiency of surface processing of metal materials is discussed. The structure and properties of protective coatings produced by exposure to pulsed plasmas are analyzed. A new direction for the production of combined coatings is considered. Their structure and properties were studied by the example of Fe, Cu, steels, and alloys, including titanium alloys; the modification process was shown to be controllable by the action of pulsed plasma jets. The physical factors that affect the modification process and the coating deposition, and their effect on the structure and properties of metallic, ceramic – metal, and ceramic coatings were analyzed.

The present paper describes the process of high speed electron beam evaporation of inorganic substances under vacuum and process parameters controlling the deposition, structure and properties of thick condensates (films). Considered are examples of single phase and multiphase metal, metal–ceramic, cermet and ceramic condensates of the thickness from several micrometres to several millimetres with dispersed, multilayer, porous and graded structures in a broad range of structural element dimensions. Dimensional effects in the structure and mechanical properties of thick condensates are noted. Areas of practical application of inorganic materials deposited from the vapour phase are described.

Abstract The anode boundary layer in atmospheric pressure arc discharges is studied numerically on the basis of the hydrodynamic (diffusion) equations for plasma components. The governing equations are formulated in a unified manner without the assumptions of thermal equilibrium, ionization equilibrium or quasi-neutrality. For comparison, a quasi-neutral model of the anode layer is also considered. The numerical computations are performed for an argon arc at typical values of the current density in anode layers (500–2000 A cm −2 ). The results of numerical modelling show that the common collisionless model of the sheath fails to describe the sheath region for the problem under consideration. For this reason, a detailed analysis of the anode sheath is performed using the results of unified modelling. In addition, the distributions of plasma parameters in the anode layer are analysed and the basic characteristics of the layer (anode voltage drop, sheath voltage drop, anode layer thickness, sheath thickness, heat flux to the anode) are calculated. Our results are found to be in good agreement with the existing theoretical predictions and experimental data. The dependence of the anode layer characteristics on the current density is also discussed.

Using of welding technologies to produce metal volume objects allows considerable lowering of their manufacturing cost at simultaneous increase in productivity, compared to SLS-and SLM-processes. The most perspective welding technology of additive manufacturing of three-dimensional objects is plasma-arc technology with application of wires or powders. It allows creating at comparatively low heat input quality volumetric products with wall thickness from 3 to 50 mm from alloys based on Fe, Ni, Co, Cu, Ti, Al, as well as composite materials, containing refractory components.

The current state of 3D technologies for manufacturing of volumetric metal products is analyzed. It is shown that the main advantages of additive welding technologies for obtaining three-dimensional metal structures of complex shape in comparison with SLM-technologies are:– increase of the process productivity by 1–2 orders with the same power consumption; 3–10 times reduction in the cost of equipment;– the possibility of increasing the overall dimensions of the created parts by a factor of 10 or more;– expansion of the range of used consumables (powders, wires, composite materials);– increase in the utilization factor of consumables by 20–50 %.The main drawbacks of additive welding technologies for the production of three-dimensional metal structures are quite large dimensions of the heat-affected zone and the build-up layer. This leads to the emergence of undesirable temperature gradients, the accumulation of residual stresses and, as a result, a decrease in performance. One of the methods for eliminating these drawbacks is to increase the thermal locality of the energy source. For example, the use of non-transferred arc plasma.The analysis of additive plasma-arc welding technologies and own research has shown that their advantages are:– high (5...50 kg/h and more) performance;– the possibility of obtaining sufficiently thin (1.5...5.0 mm) walls with a relatively small overheating;– about 5-fold saving of materials in combination with the increase in the quality (for example, strength and density) of the resulting metal parts, in comparison with the traditional methods of mechanical manufacture.

Cu) precipitates. The ultimate tensile strength and elongation reached 620 ± 18 MPa and 22.3 ± 2.2%, exhibiting excellent strength-ductility synergy. Grain boundaries, dislocation, solid solution atoms, and precipitates all contributed to the yield strength of the materials, among which precipitates occupied a dominant position, contributing approximately 56.07%. A new "incoherent-coherent interact" strain-hardening mechanism was also clarified, which was believed to be promoted in other heat-treatable alloy systems, especially with multi-step metastable phase transitions.

Antimicrobial and antiviral nanocomposites based on polylactic acid (PLA) and chitosan were synthesized by a thermochemical reduction method of Ag+ ions in the PLA-Ag+-chitosan polymer films. Features of the structural, morphological, thermophysical, antimicrobial, antiviral, and cytotoxic properties of PLA-Ag-chitosan nanocomposites were studied by X-ray diffraction (XRD), transmission electron microscopy (TEM), differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), and antiviral, antimicrobial, and cytotoxic studies. The effects of temperature and the duration of reduction of Ag+ ions on the structure of PLA-Ag-chitosan nanocomposites were established. During the thermochemical reduction (T = 160 °C, t = 5 min) of silver palmitate ions in PLA-Ag+-chitosan polymer films, Ag nanoparticles with an average size of 4.2 nm were formed. PLA-Ag-chitosan polymer nanocomposites have strong antimicrobial activity against S. aureus and E. coli strains. In particular, for PLA-chitosan samples containing 4% Ag, the diameters of the S. aureus and E. coli growth inhibition zones were 25.8 and 25.0 mm, respectively. The antiviral activity of the nanocomposites against influenza A virus, herpes simplex virus type 1, and adenovirus serotype 2 was also revealed. The PLA-4%Ag-chitosan nanocomposites completely inhibited the cytopathic effect (CPE) of herpes virus type 1 by 5.12 log10TCID50/mL (high antiviral activity) and the development of the CPE of influenza virus and adenovirus by 0.60 and 1.07 log10TCID50/mL (relative antiviral activity). The obtained nanocomposites were not cytotoxic; they did not inhibit the viability of MDCK, BHK-21, and Hep-2 cell cultures.

BACKGROUND: New microplasma spray (MPS) equipment to deposit calcium phosphate (CaP) ceramic coatings onto titanium substrates has been developed. With this apparatus, it is possible to spray fine particles, as well as to apply textured hydroxylapatite coatings onto titanium surfaces. Moreover, due to the low heat power of the microplasma jet, overheating of the powder particles as well as excessive local overheating of the substrate is reduced. Furthermore, because of the small laminar plasma jet, it is possible to achieve high spray efficiency in the case of spraying of dental implants. Additionally, the low level of noise (25-50 dB) and hardly any dust makes it possible to operate the MSE under normal workroom conditions. OBJECTIVE: The aim of this study was to examine the biological properties of different MPS - CaP coatings on titanium implants when inserted into the femoral condyle of goats. MATERIAL AND METHODS: For histomorphometrical evaluation as well as mechanical testing, 48 screw-type titanium implants were inserted into the femoral condyles of 12 goats each. The implants were either coated with a conventionally plasma-sprayed CaP ceramic, MPS CaP ceramic, or acid-etched without an additional CaP coating. Six and 12 weeks after implantation, the animals were sacrificed and bone-to-implant contact, amount of bone, as well as mechanical bone fixation were evaluated. RESULTS: For bone-to-implant contact no statistically significant difference was found between the different CaP coatings. However, statistically significant differences were found between non-coated, acid-etched titanium implants and CaP-coated implants after 6 and 12 weeks of healing. The bone values were not statistically significantly different between the different CaP coatings at 6 and 12 weeks. Furthermore, CaP ceramic-coated implants showed statistically significantly higher torque values compared with the non-coated implants after 6 and at 12 weeks of healing. No significant differences existed between the various types of CaP coatings. CONCLUSION: On the basis of our observations, we conclude that conventionally plasma-sprayed CaP ceramic-coated implants, as well as MPS-coated implants have a comparable effect on adjacent bone response.

Studies were carried out to establish the mechanisms of structure formation during crystallization of polymer composites based on polyethylene, polypropylene or polycarbonate filled with copper microparticles. The researches were executed using a technique, the first stage of which consisted in the experimental determination of crystallization exotherms of composites, and the second – in the theoretical analysis based on the obtained exotherms of the structure formation characteristics. A complex of studies on determination of crystallization exotherms for investigated microcomposites was carried out. The regularities of the cooling rate influence of composites, the method of their production and the mass fraction of filler on the temperature level of the beginning and ending of crystallization, the maximum value of the reduced heat flux, etc. were established. It is shown that for the applied methods of obtaining composites the increase of their cooling rate causes the decrease of the indicated temperatures and heat flux. It is established that the value of the mass fraction of the filler has a less significant effect on the characteristics of the crystallization process.The regularities of structure formation of polymer composites at the initial stage of crystallization with the involvement of data on crystallization exotherms and nucleation equations are investigated. The presence of planar and three-dimensional mechanisms of structure formation at this stage has been established. It is shown that the ratio of these mechanisms is influenced by the type of polymer matrix and the method of obtaining composites.For the second stage of crystallization, which occurs in the entire volume of the composite, the results of experiments on crystallization exotherms were analyzed on the basis of the Kolmogorov-Avrami equation. It is shown that the structure formation of polyethylene-based composites occurs by the three-dimensional mechanism, and on the basis of polypropylene and polycarbonate – by the mechanism of the stressed matrix

In repair of aircraft structures of magnesium alloy ML10, the argon arc non-consumable electrode welding is used. In this case, the residual welding stresses occur in repair welds, being one of the causes for reducing the service characteristics of the restored products. Residual stresses arise as a result of welding. Post-weld heat treatment is used to reduce the residual stresses. The heat treatment, which occurs after welding, increases the cost of repair. This leads to the search for alternative methods to control the stressed state of welded joints, one of which is electrodynamic treatment, which reduces the level of residual stresses in repair welds, and as a consequence, the cost of the welding repair in restoring aircraft structures. It was found from the results of experiments carried out, that the electrodynamic treatment allows reduces the initial level of stresses in welded joints, reaching 120 MPa, to 30 MPa, and at definite geometric characteristics of the specimens forming the field of compressive stresses, the values of which are equal to –50 MPa. It is shown that the optimum distance between the zones of treatment, being 5 mm, provides the guaranteed covering the zones of electrodynamic effect and, as a consequence, the maximum efficiency of the electric dynamic treatment.

The demand for orthopedic implants is increasing, driven by a rising number of young patients seeking an active lifestyle post-surgery. This has led to changes in manufacturing requirements. Joint arthroplasty operations are on the rise globally, and recovery times are being reduced by customized endoprostheses that promote better integration. Implants are primarily made from metals and ceramics such as titanium, hydroxyapatite, zirconium, and tantalum. Manufacturing processes, including additive manufacturing and thermal plasma spraying, continue to evolve. These advancements enable the production of tailored porous implants with uniform surface coatings. Coatings made of biocompatible materials are crucial to prevent degradation and enhance biocompatibility, and their composition, porosity, and roughness are actively explored through biocompatibility testing. This review article focuses on the additive manufacturing of orthopedic implants and thermal plasma spraying of biocompatible coatings, discussing their challenges and benefits based on the authors’ experience with selective laser melting and microplasma spraying of metal-ceramic coatings.

Properties of the agglomerated (ceramic) fluxes, processing technique, and fields of their application are considered.

Abstract Herein, we analyzed the morphology of atmospheric plasma-sprayed (APS) coating on medical 316L stainless steel and its influence on the physical and electrochemical properties of implant application. Fivetypes of coatings were examined: hydroxyapatite (HAp), titanium (Ti), zirconium (Zr), Ti/HAp and Zr/HAp. The base properties of the coatings were analyzed via chemical and phase composition, surface topography, surface wettability and in particular the corrosion resistance in Ringer solution in immersed conditions and potentiodynamic test, and EIS analysis. APS coating of pure HAp on 316L stainless steel showed poor cohesive bonding to the substrate material, whereas the application of Ti and Zr interlayer prior to HAp deposition improved surface morphology and coating properties. The beneficial effect of Ti and Zr interlayer under HAp layer on binding was demonstrated. HAp containing coatings (HAp, Ti/HAp and Zr/HAp) show Ca/P ratio greater than 1.8, which may positively influence the differentiation of osteogenic cells and good adhesion to bones. Among the studied materials, the composite coatings with Zr or Zr/HAp showed favorable physicochemical properties and the highest corrosion resistance in Ringer solution.

This paper reports the experimental study carried out to establish the dependence of the thermal conductivity of polypropylene-based nanocomposites filled with carbon nanotubes on the main parameter of the temperature regime of their manufacturing ‒ the level of overheating a polymer melt relative to its melting point. The study has been conducted for nanocomposites that were manufactured by applying a method based on the mixing of components in the polymer melt applying a special disk extruder. During the composite manufacturing process, the level of melt overheating varied from 10 to 75 K, with the mass share of filler ranging from 0.3 to 10.0 %. It is shown that increasing the overheating of a polymer melt causes an increase in the thermal conductivity of the composites. However, when the overheating has reached a certain value, its further growth does not increase the thermal conductivity of nanocomposites. Based on the established pattern, the rational level of this overheating has been determined. That resolves the tasks of manufacturing highly heat-conducting nanocomposites and implementing appropriate energy-saving technology. Data have been acquired on the effects of the impact of the amount of polymer melt overheating on the values of the first and second percolation thresholds for the examined nanocomposites. It is established that the value of the first percolation threshold is more sensitive to the specified amount of overheating. The dependences of the density of the examined composites on the level of polymer melt overheating have been derived. The correlation between a given dependence and the nature of a corresponding change in the thermal conductivity of the composites has been established. Applying the proposed highly heat-conducting nanocomposites is promising for micro and nanoelectronics, energy, etc.

The prospects of hybrid laser-plasma cutting of metals have been justified, a design of an integrated plasmatron for hybrid cutting was proposed and the results of laser-plasma cutting of carbon sheet structural steels using such an integrated plasmatron were forecasted. It was shown that in order to minimize losses of laser radiation and obtain maximum penetration, it is advisable to assemble the integrated plasmatron according to a coaxial scheme with an axial arrangement of laser radiation and a minimum inclination of non-consumable electrodes (one or more), the distance from the working end of which to the axis of the laser beam should lie in the range of 2...3 mm. The diameter of the plasma-forming nozzle should lie within 2–5 mm and depth of focus under the surface of the cut sheet during hybrid cutting should be 1–2 mm. To simulate the processes of laser, plasma, and hybrid cutting, the SYSWELD software package was used which became possible due to taking into account the characteristic for cutting effect of removing sections of molten material in the cutting zone, performed by replacing the maximum overheating temperature during the calculation with the initial temperature (20 °C). The main parameters of the regimes of laser-plasma cutting were established which has made it possible to obtain minimum HAZ size with cut quality approaching that of the laser cut. At the same time, hybrid cutting requires an energy input of approximately half that of the air-plasma one. An increase in the speed of hybrid cutting by increasing the pressure and consumption of working gases makes it possible to compare energy input with the same indicator of gas laser cutting with more than a three-fold increase in the productivity of the process

Welding is used extensively in the construction and repair of underwater pipelines. Recently, the volume of application of underwater welding in these operations has been expanded considerably. Thi...

Abstract The present work was aimed at the development of a new technological process: a post-weld electrodynamic treatment of welded joints by pulses of a high-density current. Generators of the pulse current and electrode devices, realizing the preset parameters of electrodynamic effects at single- and two-channel schemes, were designed and manufactured. The results of experimental investigations, carried out on specimens of base metal and welded joints, showed that the electrodynamic treatment has a positive effect on the structure of the treated metal and allows the residual stresses in welded joints to decrease gently, increasing their resistance to fatigue and brittle fracture as well as eliminating the distortion deformations in thin-walled elements of structures. The developed technologies and equipment gave an opportunity to perform the electrodynamic treatment of welded joints of hull structures of ships of aluminum alloy AMg6 and repair welds of an intermediate casing of the aircraft engine of heat-resistant magnesium alloy ML10, thus promoting an increase in their service reliability and life.

One of the most important directions in the development of additive manufacturing or three-dimensional (3D) printing technologies is the creation of functional materials, which allow not only prototyping but also the manufacturing of products with functional properties. In this paper, poly-lactide acid (PLA) /carbon black (CB) composites with segregated (ordered) structure have been created. Computer simulation based on the Mamunya geometrical model showed that the CB content within φ = 2.5–5 vol.% in the polylactide matrix leads to the formation of a continuous electrically conductive phase with an increase of electrical conductivity σdc above the percolation threshold. The simulation results were experimentally confirmed by optical microscopy and studies of the electrical conductivity of the composites. It was found that increasing CB content from φ = 1 vol.% to φ = 7 vol.% in the composites causes insignificant (due to the segregated structure) phase changes in the polylactide matrix and improves the thermal properties of composites. Electrically conductive filaments for Fused Deposition 3D Printing (FDM) were developed from PLA/CB composites and then 3D printed. A correlation between the electrical conductivity σdc and the CB content φ for base composites, filaments produced from them, and final 3D samples, has been found. Conductivity varies within σdc = 3.1·10−11 − 10·10−3 S/cm for the filaments and σdc = 3.6·10−11 − 8.1·10−4 S/cm for the final 3D-products.

The Paton Welding Journal, 2016, №06. International Scientific-Technical and Production Journal «The Paton Welding Journal» «The Paton Welding Journal» has been published monthly since 2000 in English, ISSN 0957-798X. «The Paton Welding Journal» is a cover-to-cover English translation of the «Avtomaticheskaya Svarka» (Automatic Welding) journal. The «Avtomaticheskaya Svarka» journal has been published monthly since 1948 in Russian, ISSN 005-111X.

The Paton Welding Journal, 2016, №06. International Scientific-Technical and Production Journal «The Paton Welding Journal» «The Paton Welding Journal» has been published monthly since 2000 in English, ISSN 0957-798X. «The Paton Welding Journal» is a cover-to-cover English translation of the «Avtomaticheskaya Svarka» (Automatic Welding) journal. The «Avtomaticheskaya Svarka» journal has been published monthly since 1948 in Russian, ISSN 005-111X.