The development of Perm and Indian scientists will increase the accuracy and efficiency of the production of aircraft and rocket parts

13/04/2021
Perm scientists together with colleagues from India have developed a unique technology that increases the efficiency of 3D printing of complex metal products for aircraft and missiles. The economic effect of the new technology is 34% higher than the existing ones.

The development is based on the research of scientists from Perm Polytechnic, Thapara Institute of Engineering and Technology (Patiala, India) and Beanta College of Engineering and Technology (Gurdaspur, India). Scientific and technological support of mechanical engineering is among the priorities of the Perm REC "Rational Subsoil Use”

The casting process is based on the creation of a product model, which is covered with a ceramic shell mold. Then the model is burned in a furnace and molten metal is poured into a hollow ceramic mold. The quality of the metal part will depend on the accuracy of this shape. To keep it intact, it is necessary to develop a special structure of the model and modes of its burning, scientists believe.

- Now styrofoam or wax is used for the production of burnt and melted models of experimental parts. However, these materials are expensive and do not provide the required accuracy in the manufacture of large-sized and complex products. We proposed to create models from photopolymers with an adjustable cellular structure. This method will ensure high accuracy of model manufacturing, its strength when applying the mold and minimal ash formation during burning. The technology will improve the quality of the castings obtained, which is very important in such high-tech industries as mechanical engineering, rocket science and aviation," notes the author of the study, associate professor of the Department of Innovative Engineering Technologies at Perm Polytechnic University, Candidate of Technical Sciences Timur Ablyaz.

Photopolymer models of parts with an adjustable cellular structure are "grown" on a 3D printer and burned out under certain temperature conditions. To determine the necessary parameters of 3D printing, the researchers developed a computer model in the ANSYS program. They conducted a series of experiments to identify patterns of changes in the physical and mechanical properties of the photopolymer material during heating. As a result, scientists have determined the optimal temperature conditions for burning models that will ensure an efficient and stable production process.

– We found out that if the burned model is filled with a photopolymer by 85%, this will keep the maximum stresses in the ceramic shell form at 6.5 MPa. Such conditions will reduce the marriage when removing the material. The presence of cells will reduce the material consumption for the production of the model and

it will reduce the amount of ash when it is burned. As a result, manufacturers will be able to reduce the number of defects and cracks in products, the scientist explains.

With the help of the new technology, it will be possible to reduce the cost of manufacturing parts for aircraft and missiles. The development has already aroused interest from industrial production.