Search results for: Lubov Magerramova

Authors: Vladimir Isakov, Evgeniy Rykov, Lubov Magerramova, Nikolay Emmaussky

Abstract:

For the manufacture of critical hollow products, a laser narrow-seam welding scheme based on the supply of a laser beam into the inner cavity has been developed. The report presents the results of comprehensive studies aimed at creating a sealed weld that repeats the geometric shape of the inner cavity using a rotary mirror. Laser welding of hard-to-reach places requires preliminary modeling of the process to identify defect-free modes performed at the highest possible welding speed. Optimization of the technological modes of the welded joint with a ratio of the seam width to its depth equal to 1/5 of the thickness of the Ni superalloy 6.0 mm was performed using the Verhulst limited growth model in a discrete representation. This mathematical model in the form of a recurrence relation made it possible to numerically investigate the entire variety of laser melting modes: chaotic; self-oscillating; stationary and attenuated. The control parameters and the parameter of the order to which other variables of the technological system of laser welding are subordinated are established. In it, the coefficient of relative heat capacity of the melt bath was used as a control parameter, characterizing the competition between the heat input by the laser and the heat sink into the surrounding metal. The parameter of the order of the narrow–seam laser welding process, in this interpretation, is a dimensionless value of the penetration depth, which is an argument of the function of the desired logistic equation. Experimental studies of narrow-seam welding were performed using a copper, water-cooled mirror by radiation from a powerful fiber laser. The obtained results were used to validate the evolutionary mathematical model of the laser welding process.

Keywords: laser welding, internal cavity, limited growth model, ni-superalloy

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Authors: Liubov Magerramova, Mikhail Petrov, Vladimir Isakov, Liana Shcherbinina, Suren Gukasyan, Daniil Povalyukhin, Olga Klimova-Korsmik, Darya Volosevich

Abstract:

Aircraft engines are developing along the path of increasing resource, strength, reliability, and safety. The building of gas turbine engine body parts is a complex design and technological task. Particularly complex in the design and manufacturing are the casings of the input stages of helicopter gearboxes and central drives of aircraft engines. Traditional technologies, such as precision casting or isothermal forging, are characterized by significant limitations in parts production. For parts like housing, additive technologies guarantee spatial freedom and limitless or flexible design. This article presents the results of computational and experimental studies. These investigations justify the applicability of additive technologies (AT) to reduce the weight of aircraft housing gearbox parts by up to 32%. This is possible due to geometrical optimization compared to the classical, less flexible manufacturing methods and as-casted aircraft parts with over-insured values of safety factors. Using an example of the body of the input stage of an aircraft gearbox, visualization of the layer-by-layer manufacturing of a part based on thermal deformation was demonstrated.

Keywords: additive technologies, gas turbine engines, topological optimization, synthesis process

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Authors: Liubov Magerramova, Eugene Kratt, Pavel Presniakov

Abstract:

A detailed analysis has been performed for several schemes of Gas Turbine Wheels production based on additive and powder technologies including metal, ceramic, and stereolithography 3-D printing. During the process of development and debugging of gas turbine engine components, different versions of these components must be manufactured and tested. Cooled blades of the turbine are among of these components. They are usually produced by traditional casting methods. This method requires long and costly design and manufacture of casting molds. Moreover, traditional manufacturing methods limit the design possibilities of complex critical parts of engine, so capabilities of Powder Metallurgy Techniques (PMT) were analyzed to manufacture the turbine wheel with air-cooled blades. PMT dramatically reduce time needed for such production and allow creating new complex design solutions aimed at improving the technical characteristics of the engine: improving fuel efficiency and environmental performance, increasing reliability, and reducing weight. To accelerate and simplify the blades manufacturing process, several options based on additive technologies were used. The options were implemented in the form of various casting equipment for the manufacturing of blades. Methods of powder metallurgy were applied for connecting the blades with the disc. The optimal production scheme and a set of technologies for the manufacturing of blades and turbine wheel and other parts of the engine can be selected on the basis of the options considered.

Keywords: additive technologies, gas turbine engine, powder technology, turbine wheel

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