SDTO “Energomash”, Volgodonsk, Russia:

V. A. Yadryshnikov, Head of Engineering and Design Department

¹SDTO “Energomash”, Volgodonsk, Russia ; ²Volgodonsk Engineering-Technical Institute — a branch of National Research Nuclear University “MEPhI” (Moscow Engineering Physics Institute), Volgodonsk, Russia:

E. I. Kolokolov, Technical Director¹, Assistant Professor of a Chair “Mechanical Engineering and Applied Mechanics”²

Volgodonsk Engineering-Technical Institute — a branch of National Research Nuclear University “MEPhI” (Moscow Engineering Physics Institute), Volgodonsk, Russia:
V. A. Rudenko, Head of Institute
S. A. Tomilin, Head of a Chair “Mechanical Engineering and Applied Mechanics”, e-mail: SATomilin@mephi.ru

Design of high-vacuum process units was analysed, which found a “weak link” element, making a negative influence on their operational reliability. Such element is copper current leads, which design includes extensive and low technological welds, which quality is not completely provided by application of traditional welding practice. There was carried out the current lead design modernization, concluded in the change of cooling water channel design: several communicated deeply drilled holes. As a result, welding operations were reduced by several times and concluded only in plugs and current installing pipes welding. At the same time, the quality of the whole technological process of current lead manufacturing was considerably increased. The second stage of optimization was the decreasing of high temperature of preliminary heating, required for argon-arc copper welding, but having the negative impact on deficiency of welding connections. The existing technology blocks the welding of one element of current lead design in one pass because of the quick metal cooling after preliminary heating. Elimination of this defect carried out the full-scale experiment for comparative assessment of welding-technological properties during arc welding using impact inverter welder in various shielding mediums: argon, nitrogen and helium. The sampling, carried out in helium shielding gas medium had the better quality. The considered designtechnological optimization of manufacturing of copper current leads was worked-off and introduced into production.

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