Aleksander Babkin
@stu.lipetsk.ru
Institute of Mechanical Engineering and Transport
Lipetsk State Technical University
RESEARCH, TEACHING, or OTHER INTERESTS
Mechanical Engineering, Industrial and Manufacturing Engineering
Scopus Publications
Scopus Publications
Yiwen Li, Zhihai Dong, Junyan Miao, Huifang Liu, Aleksandr Babkin, and Yunlong Chang
Emerald
Purpose This paper aims to anticipate the possible development direction of WAAM. For large-scale and complex components, the material loss and cycle time of wire arc additive manufacturing (WAAM) are lower than those of conventional manufacturing. However, the high-precision WAAM currently requires longer cycle times for correcting dimensional errors. Therefore, new technologies need to be developed to achieve high-precision and high-efficiency WAAM. Design/methodology/approach This paper analyses the innovations in high-precision WAAM in the past five years from a mechanistic point of view. Findings Controlling heat to improve precision is an effective method. Methods of heat control include reducing the amount of heat entering the deposited interlayer or transferring the accumulated heat out of the interlayer in time. Based on this, an effective and highly precise WAAM is achievable in combination with multi-scale sensors and a complete expert system. Originality/value Therefore, a development direction for intelligent WAAM is proposed. Using the optimised process parameters based on machine learning, adjusting the parameters according to the sensors’ in-process feedback, achieving heat control and high precision manufacturing.
Junyan Miao, Yiwen Li, Zhihai Dong, Huifang Liu, Aleksandr Babkin, and Yunlong Chang
Springer Science and Business Media LLC
Tianhua Wang, Yiwen Li, Yunhe Mao, Huifang Liu, Aleksandr Babkin, and Yunlong Chang
Springer Science and Business Media LLC
Yiwen Li, Zhihai Dong, Huifang Liu, Aleksandr Babkin, Boyoung Lee, and Yunlong Chang
Springer Science and Business Media LLC
Zhihai Dong, Yiwen Li, Boyoung Lee, Aleksandr Babkin, and Yunlong Chang
Springer Science and Business Media LLC
Honglei Zhao, Yiwen Li, Yajie Sun, Zhihai Dong, Huifang Liu, Aleksandr Babkin, and Yunlong Chang
Informa UK Limited
ABSTRACT The wire arc additive manufacturing (WAAM) method has a high material utilization rate and is superior to the casting method. However, the higher the dimensional accuracy required for additive manufacturing components and the more complex the components are, the more difficult it is to guarantee their quality. The subsequent processing requires a large amount of labour cost. In this study, a track optimization method is proposed to achieve the quality control of 2319 aluminium alloy additive manufacturing components, which can improve the forming accuracy and optimize the component performance. The experimental results show that multi-track stacking can effectively reduce the heat accumulation in the deposition process. The component forming accuracy is improved by about 70%, the tensile strength by about 6% and the yield strength by about 15%. The influence of deposition track on the forming accuracy and quality of WAAM components has rarely been studied.
Zhihai Dong, Yiwen Li, Hong Wu, Aleksandr Babkin, and Yunlong Chang
Springer Science and Business Media LLC
Dan Liu, Boyoung Lee, Aleksandr Babkin, and Yunlong Chang
MDPI AG
Additive manufacturing technology is a special processing technology that has developed rapidly in the past 30 years. The materials used are divided into powder and wire. Additive manufacturing technology using wire as the material has the advantages of high deposition rate, uniform composition, and high density. It has received increasingly more attention, especially for the high efficiency and rapid prototyping of large-size and complex-shaped components. Wire arc additive manufacturing has its unique advantages. The concept, connotation, and development history of arc additive manufacturing technology in foreign countries are reviewed, and the current research status of arc-based metal additive manufacturing technology is reviewed from the principles, development history, process, and practical application of arc additive manufacturing technology. It focuses on the forming system, forming material, residual stress and pores, and other defect controls of the technology, as well as the current methods of mechanical properties and process quality improvement, and the development prospects of arc additive manufacturing technology are prospected. The results show that the related research work of wire arc additive manufacturing technology is still mainly focused on the experimental research stage and has yet not gone deep into the exploration of the forming mechanism. The research work in this field should be more in-depth and systematic from the physical process of forming the molten pool system from the perspectives of stability, the organization evolution law, and performance optimization. We strive to carry out wire arc additive forming technology and theoretical research to promote the application of this technology in modern manufacturing.
Hong Wu (吴弘), Yunlong Chang (常云龙), Ziqi Guan (关子奇), Alexandr Babkin, and Boyoung Lee
Elsevier BV
H. Wu, Y. L. Chang, Alexandr Babkin, and Boyoung Lee
Springer Science and Business Media LLC
邹文凤, 李逸文, 梅强, BabkinAleksandr and 常云龙
短路过渡CO2气体保护焊由于低成本、高效率、便于实现全位置焊接，广泛应用在工业制造领域，但是在焊接过程中，特别是在较高的焊接电流下，存在许多诸如飞溅，成形差，过渡过程不稳定等问题. 文中提出了一种通过施加同步磁场来改善焊接中存在的问题的新方法. 研究了不同类型的燃弧段同步磁场对焊接过程的影响. 用激光作为背光，采用高速摄像系统拍摄焊接过程，观察熔滴过渡过程，计算熔滴的大小和过渡频率等. 结果表明，在纵向同步磁场的作用下，可以有效地减少燃弧时间；施加同步磁场后，熔滴过渡频率范围都得到不同程度的缩小，熔滴过渡过程更稳定，并且在纵向磁场Im(LMF) = 200 A时，熔滴的过渡频率大幅增加；磁场作用下，带尖角的熔滴变为圆润无尖角的球形或椭球的熔滴，熔滴的尺寸减小.
Yiwen Li, Wenfeng Zou, Boyoung Lee, Aleksandr Babkin, and Yunlong Chang
Springer Science and Business Media LLC
Zi Qi Guan, Hong Xu Zhang, Xiao Guang Liu, Alexandr Babkin, and Yun Long Chang
IOP Publishing
Aluminum alloy is widely used in aerospace and shipbuilding fields, but it is microstructural and mechanical properties of weld bead are not satisfactory. In this paper, GMAW experiments under the magnetic field were carried out. The effect of magnetic field frequency on GMAW process was analyzed through taking the arc images by high-speed camera, detecting spatter rate, observing metallographic microstructural, testing tensile property and observing fracture SEM appearance. The arc shape and arc movement changed with the variation of external magnetic field frequency, which had a crucial influence on arc temperature gradient and undercooling degree and finally took effect on weld appearance and mechanical properties. The experimental results shown that the arc shape was expanded, arc temperature gradient and undercooling degree decrease, weld bead grain becomes coarse, weld appearance and mechanical properties gets worse below the magnetic field frequency of 60 Hz. The arc shape compressed, arc temperature gradient and undercooling degree increase, weld bead grain becomes refined, weld appearance and mechanical properties gets better over 60 Hz compared with conventional GMAW, the spatter rate reduced by 1.8%, the microstructural grain refined obviously and the tensile strength increased by 31.5 MPa.
Yunlong Chang, Aleksandr Babkin, and Igor Babkin
IOP Publishing
Methods for solving the inverse technological problem, which consists in determining the welding parameters by the desired properties of the welded joint, are discussed. The quality criteria of welds have been developed, which can be used to solve the inverse problems of welding technology. In the simplest case, weld sizes and their ratios may be the quality criteria. The time and space are considered discrete during the modeling thus the equations describing welding process are transcendental equations. The transcendental equations included in the systems colligate welding parameters such as current, arc voltage, travel speed, electrode diameter, its extension, physical properties of welding metal from one hand and quality criteria from another hand. One of the methods of solving the inverse technological problems is the solving of systems of transcendental equations. The mathematical support is discussed and the application of the graphical method for determining the welding parameters is shown. The possibility of determining the optimal welding parameters using methods of nonlinear programming is shown also. According the method of Lagrange multipliers one have formed the expression in which the most important weld quality criteria are used as an object function. Other quality criteria were accepted as constraints. Solving the expression obtained in the space of restrictions on welding parameters, welding parameters are obtained that deliver the local conditional optimum of the subject function.
E. A. Gladkov, S. A. Korolev, A. S. Babkin, S. N. Korobeinikov, and M. A. Sholokhov
Informa UK Limited
Abstract A method is proposed for calculating the temperature field in welding with trapezoidal oscillations of the welding arc, including the equation of the temperature field for the scheme of the moving surface heat source with normal distribution, the equation of trapezoidal oscillation in the form of the sum of Fourier series and the experimentally determined dependence of the effective radius of the heating spot of the arc r0 on the welding conditions. The dependence of the effective radius of the heating spot of the arc r0 on the welding conditions is determined by the similarity methods for welding of low-carbon and low-alloy steels in CO2 and a mixture of the gases Ar + 20% CO2. The comparison of the calculated temperatures and the results obtained in full-size experiments in welding of the pipes shows that the proposed calculation method results in sufficiently accurate determination of the temperature fields for practical applications.
E.A. Gladkov, A.S. Babkin, and V.N. Rocshchupkin
Informa UK Limited
The proposed method for determination of the effective radius of the heating spot of the arc r0 is based on the iteration calculation of the radius and depth of penetration using the equation of the moving heat source, with the heat flow distributed in accordance with the normal law. The dependences of the effective radius of the heating spot of the arc r0 on the welding conditions were determined using the method of the theory of similarity for welding low-carbon and low-alloyed steels in CO2 and a Ar +20% CO2 mixture. The derived equations with the experimentally determined coefficients are presented.
Yunlong Chang, Mingxu Liu, Lin Lu, A. S. Babkin, and Bo-Young Lee
IOP Publishing
The CO2 arc welding was carried out under a longitudinal magnetic field, and the arc shape has been studied by using a high-speed camera. From the camera images, we know that under the action of the longitudinal magnetic field, the upper end of the arc will constrict and the lower end of the arc will expand. It would become a bell-type shape and rotate at a high-speed in the optimum range of magnetic field parameters. The arc shape was simulated using a mathematical model, which was established based on experiment data and theoretical knowledge, and mechanism analysis has been carried out regarding the effect of longitudinal magnetic field on CO2 welding arcs.
Yun Long Chang, Xiao Long Liu, Lin Lu, A. S. Babkin, Bo Young Lee, and Feng Gao
Springer Science and Business Media LLC
A.S. Babkin and A.Yu. Kruchanenko
Informa UK Limited
The system for automatic design of welding technology, described in the article, can be used to improve the quality of welded joints, increase labour productivity, reduce material losses, increase technological discipline and shorten the time required for the technological preparation of production.
S.N. Korobeinikov and A.S. Babkin
Informa UK Limited
A welding conditions values calculation algorithm for low-alloy steels ensuring optimal structural composition of metal in the heat-affected zone is developed.
S.N. Korobeinikov and A.S. Babkin
Informa UK Limited
Mathematical models of the welding source of heat and supercooled austenite structural transformations, allowing for calculating structural and phase composition in the thermal action zones of the low-alloy steels welded joints accurately enough for the practical applications, are suggested.
A.S. Babkin, V.A. Golubev, V.N. Poshchupkin, and A.N. Goncharov
Informa UK Limited
The temperature of the welding arc is the most important characteristic which determines the thermal effect on the processed material and the electrode. However, in the scientific and technical literature, there is insufficient information on the measurements of the temperature of the welding arc plasma in consumable electrode welding and on investigations of the effect of the composition of gas mixtures on the arc discharge temperature. Several studies have been concerned with these questions. In Lapin – , spectroscopic methods were used to determine the temperature (6000–6400 K) of the arc in air welding with consumable iron electrodes with a diameter of 12 mm, with a constant arc gap, a current of 5–400 A (reversed polarity) and an arc voltage of 28–30 V. The experimental results show that the arc temperature in CO2 surfacing with Sv-08G2S wire with a diameter of 1.2 mm, a welding current of 80 A, reversed polarity and a voltage of 12 V is equal to 7000 ^ 300 K. It was also shown that in surfacing in argon with the same wire with a diameter of 1.2 mm, a current of 225–300 A and a voltage of 36–38 V (reversed polarity), the temperature is 4500–5800 K. In Govorov, investigations were carried out to determine the arc temperature equal to 4330–4850 K in welding in air with Sv-08 wire with a diameter of 3 mm with a chalk coating using alternating current of 60–100 A, voltage 20 V. In all the cases, the method of relative intensity of spectral lines (http://www.astro.univie.ac.at/vald/) was used: CuI – 3 FeI 4 and both CuI and FeI . Investigations into the plasma temperature of the welding arc running between a tungsten electrode– cathode and a water-cooled copper anode in argon were carried out by spectrographic methods – . In these investigations, special attention was given to using the method of absolute intensity of the spectral lines ArI. The experimental results show that at a current of 10– 25 A, the temperature changes from 8000 K at the periphery of the welding arc to 11,000 K in the vicinity of the electrode–anode. The scientific and technical literature does not contain any data on the plasma temperature of welding arcs running in the mixtures of the gases Ar þ O2, Ar þ CO2 and CO2 þ O2. Therefore, the aim of the present work is the investigation of the plasma temperature of the arc discharge in welding gas mixtures in consumable electrode welding and the determination of the quantitative dependences of the effect of the composition of the mixture on the plasma temperature. It is well known that the experimental investigation of the plasma temperature, carried out by the method of photographic photometry, is relatively accurate (the error does not exceed 10%), but it is time consuming and requires special photographic materials and equipment for the measurement of radiation intensity. The currently available devices for recording radiation, constructed on the basis of the devices with a charge connection, make it possible to determine the radiation intensity on the real timescale, including the photographic process. In the present work, the method of relative intensities was used for temperature measurements. Equipment for investigating the plasma temperature (Figure 1) consists of a DFS-542 spectrograph and a multichannel optical spectrum recording device (MOSRD) based on devices with charge connection LX511 SONY, produced by MORS Co. (Institute of Spectroscopy, Russian Academy of Sciences, Moscow region; www.ooo-mors.ru). The optical recorder of the spectrum is designed for operation in the spectral range 270–950 nm. The light flux of the arc was weakened using NS-1 neutral light filters. Arc images were projected through a three-lens illumination system onto the slit of the spectrograph 0.024 mm wide. The plasma of the electric arc at the atmospheric pressure is characterized by a specific temperature because this type of plasma shows the formation of a thermodynamic equilibrium, in which the processes of excitation and ionization can be described by Boltzmann and Saha equations. Temperature was estimated by the method of relative intensities of spectral lines using the Einstein–Boltzmann equation