CC BY
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TECHNICAL SCIENCE / «еЮУУШШиМ-ЛШТШИ» #361119), 2022
TECHNICAL SCIENCE
УДК 621.791.72
Bernatskyi Artemii Volodymyrovych,
Candidate of Technical Sciences, Senior Researcher, Head of the Department of the Specialized High-Voltage Engineering and Laser Welding, E. O. Paton Electric
Welding Institute of the National Academy of Sciences of Ukraine, 11, Kazymyr Malevych St., Kyiv, 03150, Ukraine, https://orcid.org/0000-0002-8050-5580 Lukashenko Volodymyr Andriiovych, Candidate of Technical Sciences,
Researcher of the Department of the Specialized High-Voltage Engineering and Laser Welding, E. O. Paton
Electric Welding Institute of the National Academy of Sciences of Ukraine, 11, Kazymyr Malevych St., Kyiv, 03150, Ukraine, https://orcid.org/0000-0002-9685-4654 Siora Oleksandr Vasylovych,
Researcher of the department of the specialized high-voltage engineering and laser welding, E. O. Paton Electric Welding Institute of the National Academy of Sciences of Ukraine, 11, Kazymyr Malevych St., Kyiv, 03150, Ukraine, https://orcid. org/0000-0003-1927- 790X Shamsutdinova Nataliia Oleksandrivna, Engineer of the Department the Specialized High-Voltage Engineering and Laser Welding, E. O. Paton Electric Welding Institute of the National Academy of Sciences of Ukraine, 11, Kazymyr Malevych St., Kyiv, 03150, Ukraine,
https://orcid.org/0000-0002-3525-0080 Siora Iryna Viktorivna, Candidate of Chemical Sciences,
Researcher at the Department of Surface Biomedical Problems Chuiko Institute of Surface Chemistryof the National Academy of Sciences of Ukraine, 17, General Naumov St., Kyiv, 03164, Ukraine, https://orcid.org/0000-0002-4436-8945 DOI: 10.24412/2520-6990-2022-36159-10-12 ANALYSIS OF THE PROSPECTS OF THE IMPLEMENTATION OF LASER WELDING TECHNOLOGY FOR THE PRODUCTION OF TRUCK RAILWAY WAGONS IN UKRAINE
Бернацький Артемш Володимирович,
кандидат технгчних наук, старший дослгдник, завгдувач в1дд1лу «Спец1ал1зована високовольтна технка та лазерне зварювання», 1нститут електрозварювання iM. С. О. Патона Нац1онально '1 академИ наук Украши, вул. Казимира Малевича, буд. 11, м. Кшв, 03150, Украша https://orcid.org/0000-0002-8050-5580 Лукашенко Володимир Андршович, кандидат технiчних наук,
науковий сniвробiтник вiддiлу «Спецiалiзована високовольтна технiка та лазерне зварювання», 1нститут електрозварювання iM. С.О. Патона Нацiональноi академИ наук Украти,
вул. Казимира Малевича, буд. 11, м. Кшв, 03150, Украша, https://orcid.org/0000-0002-9685-4654 Сюра Олександр Васильович,
науковий спiвробiтник вiддiлу «Спецiалiзована високовольтна технiка та лазерне зварювання», 1нститут електрозварювання iм. С.О. Патона Нацiональноi академИ наук Украти,
вул. Казимира Малевича, буд. 11, м. Кшв, 03150, Укра'та https://orcid. org/0000-0003-1927- 790X Шамсутдтова Наталгя Олександрiвна, iнженер вiддiлу «Спецiалiзована високовольтна технка та лазерне зварювання», 1нститут електрозварювання iм. С. О. Патона Нацiональноi академИ наук Украши, вул. Казимира Малевича, буд. 11, м. Ки'1'в, 03150, Укра'та https://orcid.org/0000-0002-3525-0080 Сюра 1рина Вiкторiвна кандидат хiмiчних наук, науковий спiвробiтник вiддiлу «Бiомедичних проблем поверхнi», 1нститут хiмii поверхт iм. О. О. Чуйка Нацiональноi академИ наук Украти,
вул. Генерала Наумова, 17, Кшв, 03164, Украша https://orcid.org/0000-0002-4436-8945
АНАЛ1З ПЕРСПЕКТИВ ВПРОВАДЖЕННЯ В УКРАШ1 ТЕХНОЛОГИ ЛАЗЕРНОГО ЗВАРЮВАННЯ ДЛЯ ВИРОБНИЦТВА ВАНТАЖНИХ ЗАЛ1ЗНИЧНИХ ВАГОН1В
«етуушшим-шишаи» #ш<тш®х 2022 / technical science
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Abstract.
In this article, the authors proposed the introduction of laser welding technology in the manufacture of typical structural elements of covered freight railway cars (side and end walls, doors, ceiling) to replace the technology of arc welding with a fusible electrode. Such a replacement will allow to significantly reduce the costs of material, labor and energy resources for their manufacture.
Анотаця
У дант cmammi авторами запропоновано впровадження технологи лазерного зварювання при виго-товленш типових елементiв конструкцИ критих вантажних залiзничних вагонiв (бокових та торцевих стт, дверей, стелi) на замту технологи дугового зварювання плавким електродом. Така замiна дозволить суттево зменшити витрати матерiальних, трудових та енергетичних ресурав при гх виготовлент.
Keywords: laser welding, welded joints, freight railway cars, implementation prospects.
Ключовi слова: лазерне зварювання, зварнi з 'еднання, вантажш зал1зничш вагони, перспективи впро-вадження.
The railway sector is one of the main budget-forming sectors of the economy of Ukraine [1]. The main source of revenue for railway transport is the profit from the transportation of goods in domestic and interstate connections [2]. The fleet of freight wagons of Ukraine includes more than 84 thousand wagons, while about 65 thousand wagons are in working condition, and the rest are actually out of service and are in reserve or under repair [3]. In addition, more than 80% of freight railway cars in operation on Ukrainian railways have excessive wear. With a total volume of cargo transportation of about 1 mln. tons per day, the required number of wagons is almost 145 thousand units. This condition of freight rolling stock requires a large amount of work to update the fleet of freight cars of Ukraine.
The production of new wagons of old designs does not solve the problem. The existing task of restoring the fleet of rolling stock can be effectively implemented only with the introduction of a new modern fleet of freight cars.
According to forecasts, the volume of freight transportation on Ukrainian railways will gradually increase, despite the consequences of the global financial crisis. This is due to the increase in both transit transportation and the volume of freight work in connection with the development of various sectors of the economy. Therefore, the need for rolling stock, which can provide increased reliability, productivity and economy in operation, is growing significantly.
Therefore, the development, development of production and introduction into operation of modern rolling stock of a new generation is a very urgent scientific and technical problem of state importance for the economy of Ukraine.
Railway transport provides a large part of cargo transportation. Therefore, freight wagon construction in Ukraine is a very promising industry, since railway transport is one of the important factors for the normal existence of the economy of any country. This industry in Ukraine has always been export-oriented. Until 2014, export volumes traditionally exceeded import volumes. A total of 18 enterprises work in the carriage construction of Ukraine. Enterprises of the wagon-building industry are united in the Association of Wagon Builders of Ukraine. The largest are: PJSC "Kryukivsky Wagon Building Plant", PJSC "Dniprova-gonmash", PJSC "Azovzagalmash". Most of the listed
plants produce freight cars. JSC "Ukrzaliznytsia" also produces a certain number of wagons at its own wagon repair facilities.
Abandoning the technology of arc welding with a fusible electrode and switching to laser welding will allow to reduce the level of thermal stresses and deformations of the structural elements of covered freight railway cars after the technological operation of welding. It is assumed that the main advantage of the introduction of laser welding technology should be the rejection of the technological operation of editing provided by the manufacturing technology when applying the technology of arc welding with a fusible electrode. This should become possible due to an increase in welding speeds, a decrease in the volume of remelted metal and, as a result, a decrease in the level of final deformations.
The components of resource saving are:
1. A specific reduction in the weight of rolled ferrous metals for the production of wagons due to a reduction in the material capacity of the wagons (due to the rejection of the use of anchoring wire).
2. Reduction of the specific consumption of electricity during production, due to the rejection of the relatively more energy-consuming technology of arc welding with a fusible electrode.
For many years, the carriage industry of Ukraine actually worked for the Russian market. Thus, in 20112012, according to the State Statistics Service, domestic enterprises produced a record number of freight cars - 52.3 thousand, and 47.1 thousand of them were exported (that is, about 85%), including 74.5 to the Russian market % in 2011 and 55% in 2012. Already in 2013, Russia significantly reduced purchases of Ukrainian railcars and over time completely abandoned them, having built its own production facilities. After that, "Ukrzaliznytsia" and private domestic companies became the main potential client of domestic railcar builders. This led to a decrease in the volume of purchase and production of freight cars by approximately 10 times in 2014-2015.
Ukrainian wagon manufacturers, in addition to fulfilling orders from Ukrzaliznytsia, actively cooperate with various large transport companies. However, the domestic market of railway wagons does not correspond to the industrial capacities of Ukrainian enterprises for the production of freight railway wagons. In addition, it should be noted that in 2015-2016, JSC
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TECHNICAL SCIENCE / «<g©LL©(MUM~J©U©MaL» #361119), 2022
"Ukrzaliznytsia" reoriented its own repair plants to the production of new freight cars, and according to State Statistics, in 2017, JSC "Ukrzaliznytsia" purchased 2,721 freight cars, of which 2,606 cars were built on own enterprises. In this regard, the task of reorienting own products to the needs of new sales markets is becoming urgent for domestic railcar-building enterprises. Namely, the markets of Western and Eastern Europe, the countries of the Middle East and Central Asia. In order to increase the competitiveness of products, railcar-building enterprises need to involve modern materials processing technologies in production processes to reduce the cost of production.
One of the promising directions of modernization of production in the manufacture of typical structural elements of covered freight railway cars (walls, doors, ceilings) is the replacement of the outdated technology of arc welding with a fusible electrode by modern technologies of joining materials.
The authors proposed the introduction of laser welding technology in the manufacture of typical structural elements of covered freight railway cars (side and end walls, doors, ceiling) to replace the technology of arc welding with a fusible electrode. Such a replacement will allow to significantly reduce the costs of material, labor and energy resources for their manufacture.
However, replacing the technology of arc welding with a fusible electrode for the technology of laser welding in the production of typical structural elements of covered freight railway cars requires making appropriate changes to the Technical Conditions and other governing documents for the production of freight cars.
Therefore, there is an urgent general task of the need to work on preparation for the certification of laser welding technology of typical structural elements of covered freight railway cars.
Conclusions.
To solve this problem, it is necessary to perform the following tasks.
Analyze the features of the main structural elements and determine the types of welded joints used in the manufacture of covered freight railway cars and establish the requirements for their implementation.
Perform work on preparation for the certification of the technology of laser welding of welded joints used in the structural elements of covered freight railway cars, guided by DSTU EN ISO 15614-11:2016 "Technical conditions and certification of the technology of welding metal materials. Testing of welding processes. Part 11. Electron beam and laser beam welding".
Perform work on preparation for certification of laser welding technology of typical structural elements of covered freight railway cars, guided by DSTU ISO 15613:2005 "Technical conditions and certification of technological processes of welding metal materials. Certification based on pre-production tests".
Develop technological instructions for laser welding of typical structural elements of covered freight railway cars, in accordance with DSTU ISO 156094:2008 "Technical conditions and certification of the technology of welding metal materials. Technological instruction on welding. Part 4. Laser welding".
References
1. Krykavskyy Y., Stasiuk, K. Railway infrastructure financial security: the Ukrainian case. Scientific Journal of Bielsko-Biala School of Finance and Law. 2021. T. 25. № 1. C. 10-14.
2. Kurhan M., Kurhan D. Providing the railway transit traffic Ukraine-European Union. Pollack Periodica. 2019. T. 14. № 2. C. 27-38.
3. Pittman R., Jandová M., Król M., Nekrasenko L., Paleta T. The effectiveness of EC policies to move freight from road to rail: Evidence from CEE grain markets. Research in Transportation Business & Management. 2020. T. 37. C. 100482.
