THE 80th ANNIVERSARY OF THE CHAIROF WELDING PRODUCTION

OF NTUU «KIEV POLYTECHNIC INSTITUTE»

In 1935, on the initiative of Evgeny O. Paton,the outstanding scientist and engineer, the aca-demician of the UkrSSR, the Chair of WeldingProduction was founded at Mechanical Facultyof Kiev Polytechnic Institute, and preparationof mechanical engineers on specialty «Equipmentand Technology of Welding Production» was or-ganized. The need in education of the specialistsof such a profile was caused by the requirementsof intensive development of the domestic indus-try, transport, construction and many otherbranches of the national economy. By transfer-ring the students from other specialties the firstgroups of students were formed for educating thewelding engineers at the second and third yearsof study. The first graduation of engineers ofwelding specialty (17 persons) took place in1938, and within 3 years 104 welding specialistswere educated and trained.

Many research workers of the Electric Weld-ing Institute of the Academy of Sciences of theUkrSSR, organized in 1934, took an active partin the educational process at the Chair in thoseyears, in particular, V.I. Dyatlov, V.V. Shever-

nitsky, A.M. Sidorenko, F.E. Sorokovsky. Forteaching the profile disciplines the staff membersfrom other chairs of the Institute were also in-vited. Among them the Ass. Profs I.P. Trochunand N.V. Pines, the Assistant G.K. Blavdzevich,and M.M. Bort, the Chief metallurgist of theaircraft plant. The required number of rooms foreducational process and research works was al-located for the Chair. At that stage the formationof new engineering specialty «Equipment andTechnology of Welding Production» took place.For the first time the methodological grounds foreducation and training of welding engineers weredeveloped, including an integrated system of edu-cation based on close relation between the edu-cational institution and production.

From the beginning of its foundation the Chairwas headed by the Academician E.O. Paton.However, his high duties as the Director of Elec-tric Welding Institute impeded his work in KPI,and in 1938 he was forced to leave the institution,further he still continued to render a comprehen-sive assistance to the Chair, permanently em-bodying the originally laid idea of affinity andcooperation of both organizations.

Evgeny Paton was an outstanding scientistand teacher, and that fact had a rather beneficialeffect on the quality of preparation of the weldingspecialists. In those years as the basis of educatingthe welding engineers E.O. Paton laid the im-portant methodological principles consisting inneed of combining the theoretical and practicaltraining of students, subordinating the contentof the training specialists to the practical prob-lems of welding production, high requirementsto the work of students over the educational ma-terial, in extensive use of modern achievementsof science and technology of welding for educa-tion. The scientific and pedagogical staff of theChair carefully preserves these principles evenat the present time.

In 1938, the Ass. Prof. V.L. Ulasik becamethe head of the Chair. The outbreak of the warin 1941 interrupted education of welding special-ists. KPI was evacuated to Tashkent. Manyteachers, staff, postgraduate and undergraduatestudents were mobilized, some of them moved tothe plants producing defensive products. Due to

Evgy O. Paton, the founder of the Chair, and his sonsVladimir (left) and Boris (right) near new universal auto-matic welding machine TS-17 (1949)

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the absence of teaching personnel the educationof welding production engineers in Tashkent wasnot carried out.

In 1944, after return of KPI from evacuationto Kiev, the Chair of Welding Production imme-diately resumed its activity. From July to No-vember 1944 the Cair was headed by Prof. G.I.Pogodin-Alekseev, and then from the end of 1944to 1947 by the Ass. Prof. I.P. Trochun, and fora short period in 1947, by the Ass. Prof. M.N.Gapchenko and the Assistant M.M. Bort. Therewas a strong lack of qualified scientific and peda-gogical staff. Nevertheless in short terms the staffmembers and the students of the Chair managedto restore the classrooms and laboratories de-stroyed during the war. The Chair was equippedwith the necessary welding equipment. As a re-sult, in fact, the new educational and laboratoryfacilities were created with total area of about700 m2. The first post-war graduation of me-chanical engineers on specialty «Equipment andTechnology of Welding Production» was held in1947. It became possible due to the great contri-bution of Prof. K.K. Khrenov, who headed theChair from 1947 to 1957. After K.K. Khrenovthe Chair was headed by Prof. I.P. Trochun(1957—1967) and Prof. V.I. Dyatlov (1967—1969). Since 1965, at the Chair the educationand training of electromechanical engineers onspecialty «Electrothermal Equipment» with the

specialization in electric welding installationswas opened.

In 1969, to the position of the Head of theChair (as a combining job) Prof. B.S. Kasatkin,the Head of Department of the Electric WeldingInstitute, was invited, who headed the Chair un-til June 1972. This event contributed to the sig-nificant widening and strengthening of compre-hensive and creative cooperation between theChair and the E.O. Paton Electric Welding In-stitute, especially in the field of scientific re-search. The contractual research works and train-ing of scientific personnel were essentiallyboosted through postgraduate courses and com-petition. At the same time, the difficulties asso-ciated with the limited educational, laboratoryand scientific base of the Chair were noticeablemore significantly.

In the early 1970s, the Government ofUkraine took the decision to found the Educa-tional Center for the joint training and improvingthe qualification of welding engineers on the fa-cilities of KPI and PWI. The new educationaland laboratory building (now the 23rd buildingof the National Technical University of Ukraine«KPI») of 6000 m2 area was built. In September,1977 the Chair moved to the new educationaland laboratory facilities, equipped with the mod-ern equipment and devices. For educational workthe PWI leading scientists G.I. Leskov, A.I.

Unveiling of monument Evgeny Paton at NTUU «KPI»

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Chvertko, A.G. Potapievsky, V.R. Ryabov, V.N.Zamkov, V.E. Moravsky, V.I. Makhnenko, B.A.Movchan, A.A. Rossoshinsky et al. were invitedto the Chair on the terms of a combining job.

Since 1972 to 1974, the Chair was headed byProf. M.N. Gapchenko, and since 1974 it washeaded by Prof. I.R. Patskevitch.

From 1962 to 1978, under the supervision ofV.P. Chernysh the works on creation of methodsof magnetic control of solidification of weld poolmetal (V.P. Chernysh, V.V. Syrovatka, I.V.Malinkin, V.D. Kuznetsov et al.) were carriedout at the Chair. The obtained results confirmedthe possibility of active influence on the processof primary solidification by electromagnetic stir-ring of weld pool and showed that stirring leadsto refinement of weld metal structure, and changein depth and shape of penetration.

In 1978, from the Chair of Welding Productionthe Chair of Welding Equipment was detachedunder the directorship of Prof. V.P. Chernysh,where the works on the control of solidification ofweld pool metal by the magnetic influence werecontinued, further developed in the works ofProf. R.N. Ryzhov, Dr. V.A. Pakharenko et al.

From May, 1989 to April 27, 2015, the Chair ofWelding Production was headed by Prof. V.M.Prokhorenko (the graduate from the Chair in 1962).

In 1991, from the Chair of Welding Productionthe Chair of Restoration of Machine Parts wasdetached, which by that time was headed by theAss. Prof. V.M. Dukhno, and from October, 1993it was headed by Prof. V.N. Korzh. It was chargedwith preparation of specialists on specialty «Equip-ment and Technology for Improving Wear Resis-tance of Machine Parts». At present time the Chairis called the Chair of Surface Engineering and isheaded by Prof. V.D. Kuznetsov.

On the basis of the Chair of Welding Produc-tion in 1975 the Welding Faculty resumed itswork, whose dean until 2002 was Prof. A.M.Slivinsky, the graduate of the Chair of WeldingProduction in 1960. Since 2002 until now theWelding Faculty is headed by Prof. S.K.Fomichev, who headed the Chair of ElectricWelding Equipment since 2001.

Today the Faculty consists of three specialchairs: Welding Production, Electric WeldingEquipment and Surface Engineering. The Fac-ulty prepares bachelors in the direction «Weld-ing», as well as specialists on «Equipment andTechnology of Welding Production», «WeldingMachines», «Equipment and Technology of In-creasing Wear Resistance and Restoration of Ma-chine Parts», and masters in the field of weldingscience and technology on the basis of bachelorpreparation. Currently, about 400 students arestudying at the Faculty. Besides the education

of students of the Faculty the scientists carry outa wide range of scientific research on the mostrelevant and advanced directions.

On the territorial facility of building of theWelding Faculty, the Welding Training Centerwas founded in 1977, where the UNIDO workshopand courses for improving the qualification of do-mestic specialists in the field of welding and non-destructive testing of welded joints and trainingcourses for welders-workers were opened. TheChair of Welding Production takes also an activepart in the work of the Educational Center. At themoment this direction is actively realized in theprogram of double diploma – International Weld-ing Engineer (IWE), International Welding Tech-nologist (IWT) and International Welding Inspec-tor (IWI) (according to standard DSTU ISO14731:2008). This diploma is realized on the basisof the Welding Faculty and the teachers of thechairs of the Welding Faculty form the workinggroup on training specialists on the basis of labo-ratories of the Chair.

At the end of 1994, on the initiative of A.M.Slivinsky, the Dean of the Welding Faculty, andthe Ukrainian Welding Society according to thegeneral resolution of the National Academy ofSciences of Ukraine and the Ministry of Educa-tion of Ukraine, the Ukrainian Committee forWelder Certification (UCWC) was founded. Itstechnical director was V.T. Kotik, the Ass. Prof.of the Chair of Welding Production. During theperiod of the UCWC activity, more than 700experts were trained and certified, and more than230 commissions on certification of welders wereopened in Ukraine. The database on certifyingcommission and certified welders (annually cer-tified about 10,000 persons), created by theUCWC, provide a rapid control of the certifica-tion processes as well as obtaining the informa-tion on the status and dynamics of developmentof welding production in Ukraine. Thus, the sys-tem of welders certification in Ukraine demon-strated its necessity, relevance and effectiveness,providing the high quality of welding works.

Since the moment of its foundation the re-search work gained the extensive developmentat the Chair. The postgraduate courses were or-ganized and successfully operate. The postgradu-ate students and many staff members of the Chairdefended their theses for candidate of technicalsciences degree. The teachers of the Chair pub-lished a number of books, which received a widerecognition. At the Chair the steadily developingresearch directions were formed. In particular,the staff members of the Chair under the generalsupervision of Prof. K.K. Khrenov carried out anumber of works related to the investigation ofwelding arc (V.E. Moravsky, G.B. Serdyuk,

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G.V. Vasiliev, L.A. Byalotsky). In 1949, K.K.Khrenov published fundamental monograph«Electric welding arc», which became the firstsummarized work on the subject. These workson study of arc discharge were continued on anew qualitative level with the use of electronicoscillography of arc in order to study the tran-sient processes (L.A. Zhdanov, V.L. Kovalenko).The results of these investigations are reflectedin the thesis for Cand. of Tech. Sci. Degree ofV.L. Kovalenko (2013). As a result, a new com-plex criterion for evaluation of stability of exist-ence of arc discharge was proposed, which in-cludes power and technological characteristics ofthe arc, the features of existence of alternatingcurrent arc were explained.

The other demanded direction of research ac-tivity of the Chair was the creation of new origi-nal slag systems for ceramic fluxes and develop-ment of their compositions intended for weldingand surfacing, as well as the technology of manu-facture of ceramic fluxes (D.M. Kushnerev, I.M.Zhdanov, M.P. Grebelnik et al.). The results ofinvestigations on the development and applica-tion of ceramic fluxes are described in monographof K.K. Khrenov and D.M. Kushnerev «Ceramicfluxes» published in 1954. The works were con-tinued in 1970—2015 by A.M. Slivinsky, V.N.Kopersak, V.I. Prokhorov, V.T. Kotik, O.A.Gaevsky, L.A. Zhdanov and N.M. Strelenko.During that time the unique ceramic flux forwelding the metal after oxy-fuel cutting (A.M.Slivinsky, V.T. Kotik), fused flux AN-44 for

welding of low-carbon steels of increasedstrength (A.M. Slivinsky, V.M. Prokhorov, B.N.Kopersak), fused flux AN-69 for surfacing (A.M.Slivinsky, L.A. Zhdanov), agglomerated fluxANK-45 (jointly with the PWI Department) andflux ANK-73 for surfacing (L.A. Zhdanov, N.M.Strelenko) were developed. The results of thework are reflected in numerous publications andprotected by the copyright certificates and pat-ents of Ukraine.

The development of original technologies forsurfacing of cutting tool, worn-out parts of ma-chines and mechanisms are also an important di-rection of work of the Chair of Welding Produc-tion. The works of V.D. Kuznetsov, N.A. Gor-penyuk, Yu.A. Yuzvenko, M.S. Samotryasov andB.N. Gorpenyuk should be noted.

The important works on theoretical problemsof welding were performed under the supervisionof V.I. Dyatlov, who defended the thesis for Dr.of Tech. Sci. Degree on these directions in 1963.They include original developments in the fieldof theory of freely expanding and contractedwelding arc, calculations of conditions of auto-matic submerged arc welding, electrode metaltransfer and a number of other investigations.The theoretical models of V.I. Dyatlov on arcprocesses, electrode metal transfer, metallurgicalinteraction in submerged arc welding did notloose their relevance even today. Prof. V.I. Dyat-lov dealt not only with fusion welding, but alsowith solid-state welding. At the Chair under hissupervision the thesis for Cand. of Tech. Sci.

Staff members of the Chair of Welding Production (September, 2015)

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Degree on diffusion welding in the glow dis-charge of magnetic and nonmagnetic steels wasmade by D.I. Kotelnikov, who later defendedthe thesis for Dr. of Tech. Sci. Degree on thesame subject.

Under the supervision of M.N. Gapchenko atthe Chair a number of works was carried out aimedat the study of weldability, brittle fracture of met-als and modernization of technology of weldingsteels and alloys. The results of investigations aresummarized in monograph of M.N. Gapchenko«Brittle fractures of welded joints and structures»,as well as in his thesis for Dr. of Tech. Sci. Degreedefended in 1969. Later the investigations of tech-nological strength and weldability for nickel al-loys, stainless and high-strength steels were con-tinued by A.A. Slivinsky. The results of these in-vestigations in 1998—2015 were published in nu-merous articles, including foreign ones, and theywere also included into educational book «Weld-ability of structural materials».

The works in the field of gas-flame treatmentof metals, carried out under the supervision ofM.M. Bort and A.D. Kotvitsky, gained a greatdevelopment in 1950—1960. Especially the oxy-gen cutting of metal of large thicknesses at lowpressure, pack cutting of metal, development ofthe whole series of installations for cutting theround profile, hot crops of steel casting, hot roll-ing, etc. should be noted. The fundamentallynew types of cutters were created, which founda wide application in industry. The developmentof plasma welding, surfacing and cutting of ma-terials was headed by M.N. Gapchenko. The sig-nificant results were obtained under the supervi-sion of V.N. Korzh in the field of creation of equip-ment and technologies for welding using hydro-gen-oxygen flame. The results of these investiga-tions formed the basis of the thesis for Dr. of Tech.Sci. Degree of V.N. Korzh defended in 1991.

The works in the field of welding stresses anddeformations were developed under the supervi-sion of I.M. Zhdanov and I.P. Trochun, whodeveloped the simple and descriptive methods forengineering calculations of welding stresses anddeformations in metal structures. The main re-sults of these investigations are presented inmonograph of I.P. Trochun «Inner forces anddeformations in welding». The investigations ofthermal deformation processes in welding (theworks of I.M. Zhdanov, I.M. Chertov, E.A. Kor-shenko, V.M. Prokhorenko, A.S. Karpenko,V.N. Korzh, B.V. Medko, A.K. Gonchar et al.)were intensively developed in the 1960s, carriedout under the supervision of I.M. Zhdanov. Themain directions of research are the study of regu-

larities of formation of deformations and stressesin welding process, regularities of brittle fracture,creation of new experimental methods of investi-gations and devices, development of methods forreducing residual stresses and deformations.

The results of investigations of influence ofstress-strain state of welded structures on brittlefracture of welded joints are reflected in the the-sis for Dr. of Tech. Sci. Degree of V.M. Prokho-renko «Methods for calculating stress intensityfactors and crack opening in welded joints withaccount for residual stresses», the defence ofwhich was held in 1989. The further investiga-tions of stressed state of welded structures werecarried out in the direction of development ofnew engineering methods of calculation based onthe modern conceptions about the kinetics of de-formations in welding. The result of these studieswas the thesis for Cand. of Tech. Sci. Degree ofD.V. Prokhorenko. The research results de-scribed above were partially included into edu-cational books «Stresses and deformations inwelding» by B.S. Kasatkin, V.M. Prokhorenko,I.M. Chertov, as well as «Stresses and deforma-tions in welded joints and structures» by V.M. Prok-horenko, D.V. Prokhorenko, published, respec-tively, in 1987 and 2009. In the recent years thestudy of stress-strain state in welding is successfullycontinued by the young generation of researchersD.V. Prokhorenko and A.A. Perepichaj using nu-merical methods of mathematical modeling basedon finite element method. In particular, they car-ried out modeling of stress-strain state of the mainpipeline at the site of repair of crack-like defect,study of thermomechanical processes in surfacingthe weld on the surface of a semi-infinite body,calculation of stresses and deformations for differ-ent technological schemes of welding of butt jointsof thin metal. One of the results of these studieswas the thesis for Cand. of Tech. Sci. Degree ofA.A. Perepichaj.

In the 1980s, at the Chair the new scientificdirections appeared. Under the supervision ofI.R. Patskevitch the development of matters ofthe technology of welding cast iron and investi-gations of surface phenomena in welding wasstarted. The wettability and leaking of differentpairs of liquid metals in isothermal and non-iso-thermal conditions were studied. The effect ofexternal influences on the mentioned phenomenawas determined. The results of these works aredescribed in monograph of I.R. Patskevich, V.R.Ryabov and G.F. Deev «Surface phenomena inmetals during welding» (1991). Their workswere continued by V.P. Bojko, who created aunique experimental installation for investiga-

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tion of high-temperature processes of wetting andinterphase interactions at the gas—slag—metalboundary. According to the results of researchworks the numerous papers were published. Themethods of increasing the accuracy of produc-ing welded structures were intensively devel-oped under the supervision of I.M. Zhdanov.The works were continued by V.V. Lysak. Ac-cording to the results of the work the thesis forCand. of Tech. Sci. Degree was defended andan original method for welding of thin sheetmaterial was developed.

Many interesting results were obtained byV.V. Batyuk with the staff members of the Chair(B.A. Bobin, S.N. Minakov, I.N. Grisha et al.)in the direction of development of devices andtechnology of non-destructive testing of residualwelding stresses in different welded structures.

The investigations in the field of temperatureconditions of weld pool and electrode metal dropswere carried out by V.M. Dykhno and S.M. Get-manets, and later they formed the basis of thesisfor Cand. Tech. Sci. Degree and made a significantcontribution to the study of heat content of elec-trode metal drops and pool in argon arc welding.

Since the late 1980s, at the Chair under thesupervision of S.K. Fomichev a large complex ofworks was carried out to improve the corrosionresistance of welded structures, the materials ofthese investigations formed the basis for the the-sis for Dr. of Tech. Sci. Degree defended by himin 1994. Since 1987, at the Chair under the su-pervision of I.P. Belokur the matters of flawdetection and quality control of welded jointsare intensively developed. The results of researchworks in this direction are reflected in his thesisfor Dr. of Tech. Sci. Degree, defended in 1991,and in his numerous publications.

Since the 1990s, at the Chair the direction isactively developed associated with the develop-ment of CAD systems of technological processesof fusion welding using the computer technology.Under the supervision of I.F. Korinets and withthe participation of V.P. Bojko and Yu.I. Okhajthe mathematical models for melting of steel andtitanium base metals, solid and flux-cored wiresand heating of covered electrode were developed.As a result, the original methods of calculationof conditions of mechanized and automatic arcwelding in shielding gases and under flux weredeveloped.

Modern scientific and technical directionsof the Chair of Welding Production. The re-search directions of the Chair were formed in theclose creative relationships with the PWI, withthe participation of not only the leading scientists

of the Institute, but also Boris E. Paton himself.Prof. B.E. Paton, the Director of the PWI andthe President of the NAS of Ukraine, personallyassisted in solving the problems of material andtechnical base, training of scientific personnel ofthe Chair and solving the strategic tasks of de-velopment of welding production. Below the ba-sic problematic directions of work of the Chairare considered.

Technologies and metallurgical processes inelectric arc welding:

• creation of theoretical models for calculationof gas phase composition, effect of welding con-sumables on composition of weld metal, contentof gases and nonmetallic inclusions in it duringarc welding on the basis of physical thermody-namic modeling;

• investigation of metallurgical processes inwelding and development of new fused agglom-erated fluxes and flux-cored wires for weldingand surfacing;

• study of weld metal tendency to crack for-mation on the basis of technological samples;

• investigation of arc discharge in welding andits technical characteristics on the basis of com-plex factors of stability and transient processesusing synergic power sources;

• investigation and modeling of features ofpore formation in welding;

• modeling of thermal processes of electric arcwelding;

• investigation of influence of thermal defor-mational cycles of welding on phase compositionand structure of welded joint metal;

• technological features of welding usingmodulated current with synergic regulation ofarc;

• creation of mathematical models of base andelectrode metal melting in arc fusion weldingand optimization of welding processes in shield-ing gases on their basis.

Stresses and deformations in welding:• modeling and calculation of welding stresses,

deformations and displacements of elements ofwelded structures using finite element methodbasing on the modern computer technologies;

• study of influence of technological schemesof welding on residual displacements of longitudi-nal axis of welded structures and development ofoptimal technological sequence of their welding;

• modeling of stress-strain state of weldedstructures for beam and arc welding methods;

• determination of energy input of thermalstraightening of welded one-dimensional struc-tures using engineering calculation methods.

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Diffusion welding and brazing of metals, al-loys and composite materials:

• mathematical modeling of thermal deforma-tion processes during diffusion welding and braz-ing;

• development of technologies of diffusionwelding and brazing with the controlled stress-strain state;

• investigation of influence of surface modifi-cation by highly-concentrated energy flows onproperties of diffusion-welded and brazed joints;

• creation of new materials for producing dif-fusion-welded and brazed joints.

The active development of the direction is pro-vided owing to the support of the PWI manage-ment and staff members, in particular, K.A. Yush-chenko and I.V. Krivtsun, the Academicians of theNASU, V.F. Khorunov, the Corr.-Member of theNASU, and the staff members of the National Ship-building University (Nikolaev). The great contri-bution to the performance of works on control ofstress-strain state in the process of producing jointsin the solid state was made by V.I. Makhnenko,the Academician of the NASU, and to producingof metal-ceramic joints by O.K. Nazarenko, theCorr.-Member of the NASU.

Many of the graduates of the Chair becameprominent workers of science and welding pro-duction. Among the graduates from the Chairthere are many candidates and doctors of tech-nical sciences. In this article it is difficult tomention the names of all the prominent graduatesof the Chair. We only note that many of thembecame the academicians of the NASU and man-agers of large enterprises and organizations.

In the period of 2005—2015, a significantbreakthrough in raising the scientific potentialof the Chair and Welding Faculty in general wasdone. This became possible due to the implemen-tation of a target program of preparation of Can-didates and Doctors of sciences, signed byProf. B.E. Paton and M.Z. Zgurovsky, the Aca-demician of the NASU, the Rector of NTUU«KPI», and is realized at their active support.In the frames of this program at the WeldingFaculty 5 Doctors and 10 Candidates of TechnicalSciences were prepared.

Recently, the Chair has a fruitful cooperationwith well-known companies Fronius Ukraine andBinzel Ukraine GmbH, as well as the PWI PilotPlant of Welding Equipment and Pilot Plant ofWelding Materials, where our graduates areworking. These companies are equipping thelaboratories of the Chair with innovative equip-ment, provide information stands and weldingconsumables, carry out lectures-presentations on

the latest achievements in the field of weldingproduction. The students visit these enterpriseswith a great interest.

The staff members of the Chair take an activepart in the development of international coopera-tion. In particular, Prof. V.V. Kvasnitsky,Ass. Profs L.A. Zhdanov and A.A. Slivinsky, andthe Head of the laboratory A.A. Grinyuk take anactive part in the international projects of the Chi-nese-Ukrainian E.O. Paton Welding Institute. Thejoint research and educational programs with theBelarusian State University, Otto-von-GuerickeUniversity Magdeburg (Germany), Federal Uni-versity of Uberlandia (Brazil) and organizationsof other countries, are actively carried out.

During 80 years the Chair of Welding Produc-tion prepared thousands of highly-skilled special-ists, who played an important role in developmentof welding science and production. Our graduatessuccessfully work not only in Ukraine but also inmany other countries like Germany, USA, Canada,Russia, Australia, New Zealand and Israel.

Students of the Chair in its history. Manyglorious pages to the history of the Chair werewritten down by its students. They worked ac-tively in the student construction brigades inTyumen, Sakhalin and other regions of the formerSoviet Union and also in Czech Republic.

In 1985—1987, the specialized student bri-gades of the Chair participated in the large-scalescientific and technical experiment on the construc-tion of pipelines of polyethylene pipes for gasifi-cation and water supply of towns of Novoodessadistrict of Nikolaev (Ukraine) region. This was agood example of fruitful cooperation of the Chairwith the PWI, when the students under the super-vision of teachers participated in the implementa-tion of developments of the scientists.

The students of the Chair participate con-stantly in the Ukrainian student competitions onwelding and occupy the first and prize places inthe individual and team standings. The masterand postgraduate students deliver papers at theannual scientific conferences. In 2010, our teamoccupied a prize place at the All-Ukrainian en-gineering competitions and represented Ukraineat the European competitions. The Chair wasalways famous by its activists, who participatedin organization of the Faculty Days – editionof the multi-issue student newspaper, organiza-tion of broadcasting in our building, creation ofthe student library of several thousand books onwelding. The students of the Chair contribute tothe victories of sport teams of the Faculty infootball, basketball, shaping and achieve highresults in individual sports like track-and-field

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athletics, wrestling, boxing, gymnastics, weight-lifting, sport archery. The best students of theChair as to the results of study, research andsocial works receive scholarships of EvgenyO. Paton and Boris E. Paton, as well as schol-arships of the Rector of NTUU «KPI» and themayor of Kiev.

At different times many foreign students fromChina, Iran, Vietnam, Cuba, Poland, Hungary,Bulgaria and other countries studied at the Chair.Our Ukrainian students in their turn have anopportunity to study abroad. We have a doublediploma programs with Otto-von-Guericke Uni-versity Magdeburg and the Federal Universityof Uberlandia. More than a dozen of our studentshave already received the master diplomas ofUkrainian and German sample, as well as Ukrain-ian and Brazilian sample. In the recent years thestaff members of the Chair were essentially re-newed. It was joined by young and perspectivepersonnel. Over the last 10 years the staff mem-bers of the Chair defended 6 theses for Cand. ofTech. Sci. Degree, and at the present time mostof the teachers are the associate professors of theChair. The Chair is headed by Prof. V.V. Kvas-nitsky.

Participation of the Chair in development ofdefense industry of Ukraine. From the momentof foundation of the Chair its staff members underthe supervision of Evgeny O. Paton took an ac-tive part in the work on defense subjects. Thegraduates of the Chair worked in the defenseindustry and contribution of welders to creationof tank and other machinery in 1941—1945 is well-known. Such assistance has become urgent aswell in our days.

Since September, 2014, the initiative groupof the staff members and students of the WeldingFaculty under the supervision of Dr. A.A. Sliv-insky (students A. Suprun, E. Bilytsky, post-graduate student A. Bogach, staff memberS. Nestulya, Ass. Prof. L. Zhdanov et al.) is car-rying out works on manufacture and assembly ofprotective anti-cumulative screens for armoredvehicles of the ATO forces.

Due to cooperation with the Central ResearchInstitute of Armament and Military Equipmentof the Armed Forces of Ukraine into the designof screens and technology of their manufacturea number of improvements was introduced. Thescreens successfully passed ballistic tests at thesite of the Ministry of Defence of Ukraine. Theapplication for a patent was drawn up and theworks on adoption of the screens of the giventype for the armament are carried out. Today bythe efforts of students a single production in the

mechanical workshop of the Welding Facultywas developed into a serial production of screensat one of the enterprises of Kiev. At the moment,the Faculty carries out a complete design andtechnological support of the screens manufac-ture, a set of technical documentation on thescreens for the main models of light-armouredvehicles of the AFU – BTR-80 and BMP-2 wasdeveloped.

During combat missions of the AFU, underthe enemy fire, due to anti-cumulative screensmounted on armoured vehicles the lives of manymilitary men were saved. The staff members ofthe Chair received official thanks from the AFUcommand.

By the specialists of the Welding Faculty theprotective screens were manufactured and in-stalled on armored vehicles of the mobile unitsof special operation forces of Ukraine. The coop-eration with the Ukrainian defense enterpriseson working out the technological recommenda-tions on welding of armor steels of foreign pro-duction and vibration processing of welded armorstructures was arranged.

At the present time the further investigationson the processing of working elements of thescreens are carried out to improve the effective-ness of protection and guarantee the destructionof the warhead of anti-tank ammunition.

The staff members of the Chair of WeldingProduction of the National Technical Universityof Ukraine «Kiev Polytechnic Institute» cele-brate the 80th anniversary, being fully resolvedto conduct a high-level preparation of weldingspecialists for the independent state of Ukraine.

S.K. Fomichev, V.P. Bojko,V.V. Kvasnitsky, L.A. Zhdanov,

A.A. Slivinsky,V.L. Kovalenko, NTTU «KPI»

Assembly of anti-cumulative screens on armored personnelcarrier BTR-80 of the Armed Forces of Ukraine in the ATOzone by the Chair staff members

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NEW WELDING WIRE MANUFACTURER IN UKRAINE

Manufacture of special-purpose metal structures from high-al-loyed corrosion-resistant, high-temperature, heat-resistant andhigh-strength steels is developing at a faster pace all over theworld. This is due to advance of technology in petrochemicalindustry, power engineering, construction industry, intensifi-cation of transport operation, and designers’ desire to reducethe weight and overall dimensions of metal structures. Con-sumable-electrode arc welding, gas-shielded welding and sub-merged-arc welding still remain the main technologies in fab-rication and repair of such metal structures.

The structure of Ukrainian manufacturers of welding wiresfor all arc welding processes, also those for stick electrodemanufacture, includes only manufacturers of wires from low-carbon and some low-alloyed steel grades. Production of spe-cial-purpose wires: high-alloyed corrosion-resistant, heat-re-

sistant, nickel-based, high-strength, etc., was absent in Ukraine until recently. All the above-mentioned typesof wires were imported from China, India, Russia, Italy and other countries.

In 2010, a group of enthusiasts from Boyarka (Kiev suburb) took a decision to set up modern manufactureof special-purpose welding wires in their facility. The group included graduates of Welding Chair of KievPolytechnic Institute, having experience of working at PWI and in welding consumable production, busi-nessmen and financial people. After detailed study of Ukrainian market of high-alloyed corrosion-resistant,high-temperature and other special wires (including welding wires), preparation of detailed business plan,selection of production area, preparation of engineering lines and communications, the team began imple-mentation of the project. During project preparation the most recent advances of the technology of wireproduct processing were analyzed, namely features of wire rod preparation for drawing, influence of varioustypes of drawing tools and process materials on the quality of the produced wire, kinds of finished wiresurface treatment to meet the expectations of consumers, used to working with wire, complying with therequirements of European and US standards. At this stage of project preparation, special attention was givento power efficiency of production process, as well as minimizing or complete elimination of adverse environ-mental impact of future production. Technological scheme and set of equipment for process lines were selectedonly on the basis of achieving maximum possible consumer characteristics of finished wire.

As a result of analysis of equipment supplier proposals, one main manufacturer – well-known companyLamnea Bruek, and several sub-suppliers of a number auxiliary devices from Germany, Italy, Austria, USAand India, were selected from a number of potential manufacturers, proceeding from detailed technologicalscheme of production. It should be noted that various auxiliary devices are key elements of the technologicalchain in manufacture of high-alloyed and special-purpose wires. Without these specialized additional devicesthe drawing line can only support production of general-purpose wires.

All the potential manufacturers and suppliers of process equipment were first inspected (visiting andauditing the production), in order to obtain information on the engineering level and service properties ofthe proposed equipment, its reliability, ease and safety of service. Finally, it was possible to combine in oneproduction line all the best currently known engineering solutions in manufacture of special-purpose wires.

A.N. Alimov,Technical Director of Company VITAPOLIS

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Start of production was organized by VITAPOLIS company, which began manufacturing marketable wirein July, 2015. The wires were assigned registered KHORDA trade mark.

When putting the line into operation, we performed commissioning work, using Sv-08GS and Sv-08G2Swire rods. Testing of produced general-purpose wires showed that these wires produced by our process scheme,in terms of their welding-technological properties are in no way inferior to such known wire grades asAristoRod 12.50 (ESAB) and EMK-6 Top (Boehler).

Our production line is capable of preparing for drawing and cleaning in a sound and highly reproduciblemanner the surface of wire rods, having difficult-to-remove or slight unforeseen contamination, possibledeviations of diameter, ovality, etc. Here, already at the inlet of the first drawing block, the rod surface hascharacteristic uniform metal luster, as after grinding by an abrasive tool. Ovality of wire leaving the firstdrawing block with rotating die, is not more than 0.01 mm, and its surface is super smooth. Further wiredrawing is performed with application of water-soluble stearates of sodium, calcium and drawing tools ofBremer and Paramount companies. Finish preparation of drawing tools is performed in our die shop in Bremersemi-automatic machine.

Remains of drawing lubricant are removed from the surface of finished wire by hot water at high pressure,which is followed by further polishing of the wire and covering its surface with a thin layer of antifrictioncurrent-conducting coating, containing corrosion inhibitor. Finished wire is wound on standard consumerreels of 200, 300 or 415 mm diameter, packed into plastic bags and cardboard boxes. At the request of thecustomer, the wire can be additionally packed into vacuum bags.

It should be noted that manufacture of a wide range of special-purpose wires, including those designedfor welding low-alloyed and high-strength steels, high-alloyed corrosion-resistant and heat-resistant steels,nickel-based alloys and armour steels, requires close monitoring and control of all the technological processstages.

For these purposes, testing and measuring laboratory is functioning at VITAPOLIS enterprise from thefirst days of its operation. The laboratory includes a range of equipment and set of devices for mechanicaltesting, chemical analysis, metallographic examination of raw materials and finished products. Welding-tech-nological testing section is fitted with stations for gas-shielded semi-automatic welding and mechanizedsubmerged-arc welding.

Before the start of production, we paid special attention to training production personnel, realizing thateven in the best equipment high-quality products with appropriate consumer properties can be produced onlyin the case of its operation by trained, qualified workers. Our engineers provided detailed descriptions of allthe elements of technological process, working in close contact with equipment manufacturers, technologistsfrom Germany, Sweden and Austria. After competitive selection process, all the workers had productiontraining directly in our Enterprise, in accordance with developed technological and operating manuals.Personal responsibility of each worker for the performed technological operation was introduced, with re-cording and documenting of the performed operations. Quality management system, corresponding to ISO9001, is in force at the Enterprise.

In October 2015, VITAPOLIS presented their products at the International Exhibition «Arms and Safety-2015» (Kiev), which aroused considerable interest of representatives of defence industry enterprises of Ukraineand a number of foreign countries.

By now, the first orders have been fulfilled for supplying welding wires to«Frunze Elektrod», «Gefest»and other companies. At present the Enterprise production facilities allow producing about 100 tons of weldingwire of 15 different grades per month. Company investment program envisages putting into production about30 more wire grades in 2016.

A.N. Alimov, VITAPOLIS

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