Investigation of the Quality of Joining Cylindrical Blanks by Resistance Flash-Butt Welding

Aiym Yessirkepova, Karibek Tagaevich Sherov, Medgat Mussayev, Gulnur Abdugaliyeva, Nursulu Tuliyeva, Gulerke Tattimbek, Nazerke Abisheva, A.E. Okimbayeva

2025

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DOI 10.15866/ireme.v19i9.26804
Data confidence 70 medium
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Abstract

This paper presents a study on the quality of joining cylindrical blanks by using resistance flash-butt welding. Currently, about 40% of all welded joints are made by resistance welding, which ranks highest among welding methods in mechanization and automation. Flash-butt welding accounts for 10–15% of this total. Research by both domestic and international scientists has focused on improving weld quality during butt welding has been reviewed. The study confirms that resistance butt welding is widely applied across industries and remains a relevant area of scientific interest. An experimental work on joining reinforcement bars and steel rods using resistance flash-butt welding on the MCP-25 welding machine has been conducted. Metallographic and tensile tests have been carried out to assess the weld quality. Macrostructure analysis has showed no visible flaws, cracks, or incomplete fusion in the welded joints. Tensile tests have confirmed that welded samples withstood loads from 25,000 to 40,000 N. Failure has occurred in the weld zone, indicating that the joints possess sufficient strength.