Developing technology of directed energy deposition of workpieces of parts of aircraft engines from heat-resistant nickel alloys by means of using layer-by-layer microplasma surfacing method

Authors

DOI:

https://doi.org/10.20535/2521-1943.2024.8.2(101).296932

Keywords:

depositing workpieces, powder, wire, mechanical properties, chemical composition, weld metal

Abstract

The article presents the technology of the Directed Energy Deposition (DED) process using the method of layer-by-layer microplasma surfacing with powder and wire made from a heat-resistant nickel-based high-chromium alloy of the Ni-Cr-Ti-Al system (γ´ = 3–5 %), which is used for manufacturing workpieces of gas turbine engine parts, while ensuring a given level of mechanical properties required for the parts’ further operation. The article discusses the equipment and characteristic features of the DED technology using the continuous (layer-by-layer) microplasma surfacing method. The additive deposition was implemented on the STARWELD 190H robotic installation for microplasma powder surfacing and on the integrated installation based on the FANUC robot and the SBI plasma equipment by means of using wire made from a nickel-based alloy of the Ni-Cr-Ti-Al system (γ´ = 3–5 %). Following the deposition, such operations as the heat treatment (aging 900 °С, exposure 16 hours), the machining and the quality control were conducted. A set of studies was conducted to develop the evidence base for the purpose of determining the possibility of installing deposited workpieces in engines, with the studies being as follows: determining the chemical composition of workpieces deposited by means of a technology similar to depositing workpieces; implementing metallographic studies and mechanical tests. The authors state that studies conducted showed that the chemical composition of the deposited metal is in compliance with the requirements set forth in the regulatory documentation, and the microstructure of the deposited metal after the heat treatment corresponds to the normally heat-treated state of a low-aging nickel-based high-chromium alloy of the Ni-Cr-Ti-Al system (γ´ = 3–5 %),while the level of mechani-cal properties of the deposited alloy followed by the serial heat treatment (aging 900 °С, holding for 16 hours) is not lower than the level of the forging implemented in the serial production of this type of parts.

References

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Published

2024-06-10

How to Cite

[1]
K. Balushok, S. Chygileichyk, I. Petryk, S. Sakhno, and R. Kulykovskyi, “Developing technology of directed energy deposition of workpieces of parts of aircraft engines from heat-resistant nickel alloys by means of using layer-by-layer microplasma surfacing method”, Mech. Adv. Technol., vol. 8, no. 2(101), pp. 121–129, Jun. 2024.

Issue

Section

Aviation Systems and Technologies