A method is proposed for calculating the effective thermal conductivity of porous layers formed by plasma spraying, based on data obtained from digital photographs of sections of layers. A specific two-dimensional stationary thermal conductivity problem is considered on a real slice fragment, where the thermal conductivity of air is attributed to the pores, and the thermal conductivity of the sprayed substance in the solid state is attributed to the rest. The effective thermal conductivity is determined by comparing the results of the numerical solution of such a problem with the analytical solution of a similar problem with a constant thermal conductivity, which reduces to one-dimensional. For the numerical solution of a two-dimensional stationary problem, a generalization of the well-known numerical method for solving the Laplace equation, called the Liebman process, is used. This approach was tested on the previously carried out calculations by the finite element method on a cell model with inclusions in the form of circles, which showed a good coincidence of the results. The calculation results were also compared on a two-dimensional model of circles with a three-dimensional model of balls. At the same time, it was found that the difference in the results is insignificant, which allows us to consider calculations on real two-dimensional slices acceptable for determining the effective thermal conductivity. Calculations were carried out on fragments of photographs of sections of 25 samples created under different technological modes. The results of the calculations were compared with the results on the model of circles with the same thermal conductivity of the substance and pores as in real samples, it was found that the dependence of the effective thermal conductivity on porosity, determined by the ratio of the total area of the pores to the total area of the fragment, for real samples lies much lower than for the model of circles, and in addition, has less regularity. Based on this, it is concluded that the dependence of thermal conductivity on porosity has a significant effect on the statistics of specific pore forms, the possibility of parameterization of which is subject to further research.

Keywords: porous layers, plasma spraying, porosity, thermal conductivity equation, effective thermal conductivity, effective volumetric heat capacity, difference scheme, Liebman process, model, digital photographs.

Aleksey B. Raukhvarger (Yaroslavl, Russian Federation) – Candidate of Physical and Mathematical Sciences, Associate Professor, Department of Information Systems and Technologies, Yaroslavl State Technical University (88, Moskovsky ave., Yaroslavl, 150023, Russian Federation, e-mail: ABRRS@yandex.ru).

Mikhail E. Soloviev (Yaroslavl, Russian Federation) – Doctor of Physical and Mathematical Sciences, Professor of the Department of Information Systems and Technologies, Yaroslavl State Technical University (88, Moskovsky ave., Yaroslavl, 150023, Russian Federation, e-mail: soloviev56@gmail.com).

Sergey L. Baldaev (Shcherbinka, Russian Federation) – Сandidate of Technical Sciences, Deputy General Director for Technologies of Technological Systems of Protective Coatings LLC (9A Yuzhnaya st., Shcherbinka, 108851, Russian Federation, e-mail: s.baldaev@tspc.ru).

Lev Kh. Baldaev (Shcherbinka, Russian Federation) – Doctor of Technical Sciences, General Director of Technological Systems of Protective Coatings LLC (9A Yuzhnaya st., Shcherbinka, 108851, Russian Federation, e-mail: l.baldaev@ tspc.ru).

1. Kudinov V.V., Bobrov G.V. Nanesenie pokrytii napyleniem. Teoriia, tekhnologiia i oborudovanie [Deposition of coatings by sputtering. Theory, technology and equipment]. Moscow: Metallurgiia, 1992, 432 p.

2. Davis J.R. Handbook of thermal spray technology. ASM International, 2004, 338 p.

3. Gazotermicheskoe napylenie [Gas-thermal spraying]. Ed. L.Kh. Baldaeva. Moscow: Market DS, 2007, 344 p.

4. Jhavar S., Jain N.K., Paul C.P. Development of mi-cro-plasma transferred arc (µ-PTA) wire deposition process for additive layer manufacturing applications. Journal of Materials Processing Technology, 2014, vol. 214, pp. 1102–1110. DOI: 10.1016/j.jmatprotec.2013.12.016

5. Getsov L.B. Detali gazovykh turbin [Gas turbine parts]. Leningrad: Mashinostroenie, 1982, 296 p.

6. Kolomytsev P.T. Vysokotemperaturnye zashchitnye pokrytiia dlia nikelevykh splavov [High-temperature protective coatings for nickel alloys]. Moscow: Metallurgiia, 1991, 239 p.

7. Pankov V.P., Babaian A.L., Kulikov M.V. Teplozashchitnye pokrytiia lopatok turbin avia-tsionnykh gazoturbinnykh dvigatelei [Thermal protective coatings of turbine blades of aviation gas turbine engines]. Polzunovskii Vestnik, 2021, no. 1, pp. 161‒172. DOI: 10.25712/ASTU.2072-8921.2021.01.023

8. Platunov E.S., Buravoi S.E., Kurenin V.V., Petrov G.S. Teplofizicheskie izmereniia i pribory [Thermophysical measurements and instruments]. Leningrad: Mashnostroenie, 1986, 256 p.

9. Korotkikh A.G. Teploprovodnost' materialov: uchebnoe posobie [Thermal conductivity of materials: textbook]. Tomsk: Izdatelstvo Tomskogo politekhnicheskogo universiteta, 2011, 97 p.

10. Guseinov G.G. Ustroistvo dlia opredeleniia ko-effitsienta teploprovodnosti metodom plastiny [Device for determining the heat transfer coefficient by the plate method]. Vestnik Dagestanskogo gosudarstvennogo tekhnicheskogo universiteta. Tekhnicheskie nauki, 2010, no. 17, pp. 29–38.

11. Maize K., Ezzahri Y., Wang X., Singer S., Majumdar A., Shakouri A. Measurement of thin film isotropic and anisotropic thermal conductivity using 3ω and thermoreflectance imaging. Twenty-fourth Annual IEEE Semicon-ductor Thermal Measurement and Management Symposium, 2008, pp. 185–190. DOI: 10.1109/STHERM.2008.4509388

12. Dorokhin M.V., Zdoroveishchev A.V., Kuznetsov Iu.M. Izmerenie koeffitsienta teploprovodnosti metodom statsionarnogo teplovogo potoka [Measurement of heat transfer coefficient by the steady-state heat flux method]. Nizhnii Novgorod: Nizhegorodskii gosuniversitet, 2019, 45 p.

13. Podledneva N.A., Krasnov V.A., Magomadov R.S. Opredelenie koeffitsientov teploprovodnosti i temperaturoprovodnosti za odin opyt metodom lineinogo istochnika teploty postoiannoi moshchnosti [Determination of thermal conductivity and temperature-conductivity coefficients in one experiment by the method of a linear heat source of constant power]. Vestnik AGTU, 2013, no. 2, pp. 50–55.

14. Boué C., Holé S. Infrared thermography protocol for simple measurements of thermal diffusivity and conductivity. Infrared Physics & Technology, 2012, vol. 55, pp. 376–379. DOI: 10.1016/j.infrared.2012.02.002

15. Combis P., Cormont P., Gallais L., Hebert D., Robin L., Rullier J.-L. Evaluation of the fused silica thermal conductivity by comparing infrared thermometry measurements with two-dimensional simulations. Applied Physics Letters, 2012, vol. 101, pp. 211908–211912. DOI: 10.1063/1.4764904

16. Wilson A.A., Rojo M.M., Abad B., Perez J.A., Maiz J., Schomacker J., Marisol. S. Martín-González, Borca-Tasciuc D., Borca-Tasciuc T. Thermal conductivity measurements of high and low thermal conductivity films using a scanning hot probe method in the 3ω mode and novel calibration strategies. Nanoscale, 2015, no. 37, pp. 15404–15412. DOI: 10.1039/C5NR03274A

17. Wight N.M., Acosta E., Vijayaraghavan R.K., McNally P.J., Smirnov V., Bennett N.S. A universal method for thermal conductivity measurements on micro-/nano-films with and without substrates using microraman spectroscopy. Thermal Science and Engineering Progress, 2017, vol. 3, pp. 95–101. DOI: 10.1016/j.tsep.2017.06.009

18. Solov'ev M.E., Raukhvarger A.B., Baldaev S.L., Baldaev L.Kh., Mishchenko V.I. Chislennoe modelirovanie teplofizicheskikh svoistv poroshkovykh pokrytii metallov [Numerical Modeling of Thermophysical Properties of Metal Powder Coatings]. Vestnik PNIPU. Mashinostroenie, materialovedenie, 2023, vol. 25, no. 1, pp. 5–15. DOI: 10.15593/2224-9877/2023.1.01

19. Dimitrienko Iu.I., Sokolov A.P. Metod ko-nechnykh elementov dlia resheniia lokal'nykh zadach mekhaniki kompozitsionnykh materialov [Finite element method for solving local problems of mechanics of composite materials]. Moscow: Izdatelstvo MGTU im. N.E. Baumana, 2010, 66 p.

20. Solov'ev M.E., Raukhvarger A.B., Baldaev S.L., Baldaev L.Kh., Mishchenko V.I. Vliianie uslovii plazmennogo napyleniia poroshka oksida aliuminiia na poristost' i elektricheskoe soprotivlenie pokrytiia [Effect of conditions of plasma spraying of aluminum oxide powder on porosity and electrical resistance of the coating]. Naukoemkie tekhnologii v mashinostroenii, 2023, no. 5 (143), pp. 22‒32. DOI: 10.30987/2223-4608-2023-8-14

21. Demidovich B.P., Maron I.A., Shuvalova I.Z. Chislennye metody analiza [Numerical methods of analysis]. Moscow Nauka, 1967, 368 p.

22. Kantorovich L.V., Krylov V.I. Priblizhennye metody vysshego analiza [Approximate methods of higher analysis]. Leningrad: Fizmatgiz, 1962, 708 p.

23. Samarskii A.A. Vvedenie v teoriiu raznostnykh skhem [Introduction to the theory of difference schemes]. Moscow: Nauka, 1971, 552 p.

24. Samarskii A.A. Teoriia raznostnykh skhem [Theory of difference schemes]. Moscow: Nauka, 1977, 388 p.

25. Patankar S. Chislennye metody resheniia zadach teploobmena i dinamiki zhidkosti [Numerical methods for solving problems of heat transfer and fluid dynamics]. Moscow: Energoatomizdat, 1984, 152 p.

Machine elements are subjected to various types of machining during their production. This results in surfaces with different roughness levels. The roughness level affects the durability and deformation properties of the contact structure. Lubricants and thin sliding layers are used to reduce roughness and extend service life. Studying the polymeric materials behavior under various contact conditions, their durability in the structure and how the sliding layer thickness affects the stress-strain state under a variety of extreme external factors is important. An interesting question is the influence of the steel surfaces machining nature on the contact with the polymer protective layer. It is possible to simulate the mating character by contact finite element settings without geometrical modeling. The paper considers the deformation of the protective layer from PTFE applied to a steel plate. The simulation includes two types of steel surface treatment: "torn thread" and polished surface. Since researchers often consider an ideal contact, a contact simulation was performed under ideal conditions to evaluate the assembly performance with a protective layer. Our results demonstrate that simulating the interface nature satisfies the process physics through contact settings. It can be a first approximation when analyzing the different interface nature. The sliding layer thickness influences the contact and its the stress-strain state. There is a minimal influence of the sliding layer thickness on the structure behavior in frictional contact (contact with a polished surface). The effect of the polymer – steel interface is minimal on the assembly operation at a layer thickness of 8 mm.

Keywords: PTFE, ideal contact, adhesion, frictional contact, sliding layer, contact pressure, contact shear stress, stress-strain state, polymer material, the sliding layer geometric parameters.

Anna А. Kamenskih (Perm, Russian Federation) – candidate of technical science, docent of the Department of Computational Mathematics, Mechanics and Biomechanics PNRPU (29, Komsomolsky av., Perm, 614990, Russian Federation, e-mail: anna_kamenskih@mail.ru).

Anastasia S. Krysina (Perm, Russian Federation) – student of the Department of Computational Mathematics, Mechanics and Biomechanics PNRPU (29, Komso­molsky av., Perm, 614990, Russian Federation, e-mail:
nastia.krysina@mail.ru).

Anastasia P. Pankova (Perm, Russian Federation) – junior researcher, postgraduate student of the Department of Computational Mathematics, Mechanics and Biomechanics PNRPU (29, Komsomolsky av., Perm, 614990, Russian Federation, e-mail: anstasia_pankova@mail.ru).

1.   Pnchuk L.S., Nikolaev V.I., Tsvetkova E.A., Goldade V.A. Tribology and biophysics of artificial joints. Elsevier, 2006, 350 p.

2.   Argatov I. A general solution of the axisymmetric contact problem for biphasic cartilage layers. Mechanics Research Communications, 2011, no. 38, pp. 29–33.

3.   Tukashev Zh.B., Adilkhanova L.A. Issledovanie napriazhenno-deformirovannogo sostoianiia dorozhnogo pokrytiia [Investigation of stress-strain state of road pavement]. Geologiia, geografiia i global'naia energeia, 2010, no. 2, pp. 163–166.

4.   Becker T.C., Mahin S.A. Correct treatment of rota-tion of sliding surfaces in a kinematic model of the triple fric-tion pendulum bearing. Earthquake Eng Struct Dynam, 2013, vol. 42, no. 2, pp. 311–317.

5.   Fomin D.V. Opornaia chast' mosta i ee material. Nauchnyi zhurnal inzhenernye sistemy i sooruzheniia, 2014, no. 2 (15), pp. 80–90.

6.   Bulatov M.I., Azanova I.S., Kosolapov A.F., Smirnova A.N., Saranova I.D. Issledovanie vliianiia otritsatel'nykh temperatur na opticheskie poteri volokonnogo svetovoda v zashchitno-uprochniaiushchem pokrytii na osnove poliamidokisloty [Investigation of the influence of negative temperatures on the optical losses of fiber light-guide in the protective-strengthening coating based on polyamidoacidic acidlota]. Kratkie soobshcheniia po fizike FIAN, 2019, vol. 46, no. 9, pp. 9–13.

7.   Stroganov V.F., Sagadeev E.V., Boichuk V.A., Stoianov O.V., Mukhametova A.M. Polimernye zashchitnye pokrytiia ot biokorrozii [Polymer protective coatings against biocorrosion]. Vestnik Kazanskogo tekhnologicheskogo universiteta, 2014, vol. 17, no. 18, pp. 149–154.

8.   Vatul'ian A.O., Nesterov S.A., Iurov V.O. Re-shenie zadachi gradientnoi termouprugosti dlia tsilindra s termozashchitnym pokrytiem [Solution of the gradient thermoelasticity problem for cilin-dr with thermo-protective coating]. Vychislitel'naia mekhanika sploshnykh sred,
2021, vol. 3, no. 14, pp. 253–263. DOI: 10.7242/1999-6691/2021.14.3.21

9.   Sulaiman M.H., Nordin N.H., Sukindar N.A., Dahnel A.N., Kamaruddin S. Friction and wear behaviours of hard-coateduncoated bearing steels under nano-additive oil lubrication. Lecture Notes in Mechanical Engineering, 2022, pp. 65–68.

10. Han N., Zhang H., Zhao W. et al. Condition assessment of railway bridge sliding bearing using alternating vehicle longitudinal excitation. KSCE Journal Civ. Eng., 2022, no. 26, pp. 4737–4745. DOI: 10.1007/s12205-022-0318-8

11. Wu Yi., Wang H., Li Ai., Feng D., Sha B., Zhang Yu. Explicit finite element analysis and experimental verification of a sliding lead rubber bearing. Journal of Zhejiang University-SCIENCE A., 2017, vol. 18, no. 5, pp. 363–376.

12. Rakowski W.A., Zimowski S. Polyesterimide composites as a sensor material for sliding bearings. Compo-sites: Part B engineering, 2006, vol. 37, pp. 81–88.

13. Dhanumalayan E., Joshi G.M. Performance prop-erties and applications of polytetrafluoroethylene (PTFE) – a review. Advanced composites and hybrid materials, 2018, vol. 1, pp. 247–268.

14. Kamenskih A.A., Trufanov N.A. Regularities in-teraction of elements contact spherical unit with the antifric-tional polymeric interlayer. Journal of Friction and Wear., 2015, vol. 36, no. 2, pp. 170–176.

15. Yi X., Du S., Zhang L. Composite materials engi-neering, volume 1: fundamentals of composite materials. Singapore: Springer, 2018, 765 p.

16. Sadovskaya N.V., Obvintsev A.Y., Khatipov R.S. et al. Effect of irradiation on interfacial interaction and structure formation in filled PTFE composites. Journal Surf. Investig., 2016, no. 10, pp. 917–924. DOI: 10.1134/S1027451016050128

17. Muhammad Shahzad Kamal, Abdullah Saad Sul-tan, Usamah A. Al-Mubaiyedh, Ibnelwaleed A. Hussein, Pabon M. Erratum to: evaluation of rheological and thermal properties of a new fluorocarbon surfactant–polymer system for EOR applications in high-temperature and high-salinity oil reservoirs. Journal Surfact Deterg., 2014, no. 17, pp. 985–993.

18. Cheng F., Dong L., Zheng Y., Shiyuan L. Seismic performance of bridges with novel SMA cable-restrained high damping rubber bearings against near-fault ground motions. Earthquake Engineering & Structural Dynamics, 2021, no. 51, pp. 44–65. DOI: 10.1002/eqe.3555

19. Makarov V.F., Muratov K.R. Analiz oborudo-vaniia dlia finishnoi abrazivnoi obrabotki ploskikh po-verkhnostei [Analysis of equipment for finishing blasting of flat surfaces]. Mashinostroenie, materialovedenie, 2017, vol. 19, no. 1, pp. 170–187. DOI: 10.15593/2224-9877/2017.1.11

20. Anikeev A.N., Abliaz T.R. Vliianie napriazheniia i skorosti smotki elektroda-provoloki na formirovanie sheroho­vatosti obrabotannoi poverkhnosti pri provolochno-vyreznoi elektroerozionnoi obrabotke [Influence of voltage and speed of the electrode-wire winding on the formation of roughness of the machined surface during wire-cut electrical discharge machining]. Mashinostroenie, materialovedenie, 2016, vol. 18, no. 1, pp. 175–188. DOI: 10.15593/2224-9877/2016.1.12

21. Duo Y., Jinyuan T., Wei Z., Yuqin W. Study on roughness parameters screening and characterizing surface contact performance based on sensitivity analysis. ASME. Journal Tribol., 2022, no. 144(4). DOI: 10.1115/1.4051733

22. Wang G., Han J., Lin Y., Zheng W. Investigation on size effect of surface roughness and establishment of prediction model in microforming process. Materials Today Communications, 2021, vol. 27. DOI: 10.1016/j.mtcomm.2021.102279.

23. Han J., Zhu J., Zheng W., Wang G. Influence of metal forming parameters on surface roughness and establishment of surface roughness prediction model. International Journal of Mechanical Sciences, 2019, vol. 163. DOI: 10.1016/j.ijmecsci.2019.105093.

24. Nikitin O.F. Sherokhovatost' poverkhnosti i germetichnost' kontaktnykh uplotnitel'nykh ustroistv [Surface roughness and tightness of contact sealing devices]. Mashinostroenie i komp'iuternye tekhnologii, 2013, no. 5,
pp. 101–106.

25. Zhang J., Meng Y. Boundary lubrication by ad-sorption film. Friction, 2015, no. 3, pp. 115–147. DOI: 10.1007/s40544-015-0084-4

26. Wang H., Sun A., Qi X., Dong Y., Fan B. Experimental and analytical investigations on tribological properties of PTFE. AP Composites. Polymers, 2021, vol. 13, no. 24, p. 4295. DOI: 10.3390/ polym13244295

27. Kozitsyna M.V., Trufanova N.M., Riabkova N.A. Chislenno-eksperimental'noe opredelenie reologi-cheskikh kharakteristik polimerov [Numerical-experimental determination of rheological characteristics of polymers]. Mashinostroenie, materialovedenie, 2017, vol. 19, no. 1, pp. 155–167. DOI: 10.15593/2224-9877/2017.1.10

28. Ren Y., Zhang L., Xie G. [et al.] A review on tribology of polymer composite coatings. Friction, 2021, no. 9, pp. 429–470. DOI: 10.1007/s40544-020-0446-4

29. Liang H., Zhang Y., Wang W. Influence of the cage on the migration and distribution of lubricating oil inside a ball bearing. Friction, 2022, no. 10, pp. 1035–1045. DOI: 10.1007/s40544-021-0510-8

30. Sakalo V.I., Ol'shevskii A.A. Ispol'zovanie konechno-elementnykh modelei dlia resheniia kontaktnykh zadach s uchetom sherokhovatosti poverkhnostei tel [Use of finite element models for solving contact problems taking into account roughness of body surfaces]. Transportnoe mashinostroenie, 2018, no. 11 (72), pp. 45–56.

31. Li L., Tian H., Yun Q., Chu W. Study on temperature rise distribution of contact surface under cyclic load. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 2021, no. 235(1), pp. 138–148. DOI: 10.1177/1350650120919877

32. Murashov M.V., Panin S.D. Osobennosti chis-lennogo resheniia zadachi kontaktnogo deformirovaniia sherokhovatykh tel v ANSYS [Peculiarities of numerical solution of the problem of contact deformation of rough bodies in ANSYS]. Vestnik MGTU im. N.E. Baumana. Ser. Priborostroenie, 2016, no. 1, pp. 129–142. DOI: 10.18698/0236-3933-2016-1-129-142

The formation of the properties of energy-saturated heterogeneous composite materials occurs to a decisive extent at the stage of mixing powder components with different physical, chemical and geometric characteristics in a dispersion polymer medium. The stability of the resulting properties of such materials requires the establishment of the basic technological parameters of the mixing process. The required technological parameters are established either empirically, which, as a rule, is associated with significant material and time costs, or based on the results of modeling, which takes into account the maximum possible number of influencing factors.

In order to consistently approximate the simulation results to the results of a real process, the article considers the option of taking into account the influence of the morphological and dimensional characteristics of particles of powder materials when modeling the conditions of their mixing. The projection of the surface relief of a particle in its arbitrary cross-section, estimated by the relative radius of the particle, was chosen as a morphological characteristic, and the particle size, indicators of the shape factor and the degree of particle imbalance were chosen as dimensional characteristics.

Based on the results of the analysis of the function of the relative radius of a particle, formalized by the Fourier series expansion and presented in trigonometric form with subsequent expansion into an amplitude-frequency spectrum, trends in the distribution of spectral power density were identified depending on the changes in the values of the shape factor and the degree of particle imbalance determined by the instrumental method for the accepted sample of powder and the relative radius of the particle in the accepted intervals of their changes. It is shown that it is possible to identify an integral characteristic that is sensitive to changes in the shape factor, degree of non-equiaxiality and radius of powder particles, which can refine the mixing model constructed for an ideal unit cell formed from spherical particles. The refined mixing model was verified, demonstrating its higher reliability and meeting the practical requirements.

Keywords: energy-saturated heterogeneous composite material, polydisperse powder materials, morphological and dimensional characteristics of powder particles, Fourier transform, spectral power density, duration of mixing components.

Aleh K. Kryvanos (Minsk, Republic Belarus) – PhD (military), assistant professor, Deputy General Director, State Research and Production Powder Metallurgy Association (41, Platonov str., Minsk, 220005, Republic of Belarus, e-mail: Alehkrivonos_ok@gmail.com).

Vasili М. Buloichyk (Minsk, Republic Belarus) – Doctor of Technical Sciences, Professor, Chief Researcher of the War Simulation Laboratory, Scientific research unit of the Military Academy of the Republic of Belarus (41, Platonov str., Minsk, 220005, Republic of Belarus, e-mail:
vas-mih@tut.by).

Yauheni Ya. Piatsiushyk (Minsk, Republic Belarus) – Doctor of Technical Sciences, Professor, Deputy General Director, State Research and Production Powder Metallurgy Association (41, Platonov str., Minsk, 220005, Republic of Belarus, e-mail: pet65@bk.ru).

1. Krivonos O.K., Il'iushchenko A.F., Petiushik E.E. Metodologiia razrabotki energonasyshchennogo getero-gennogo kompozitsionnogo materiala [Methodology for development of energy-rich heterogeneous composite material]. Poroshkovaia metallurgiia: sbornik nauchnyh trudov. Ed. A.F. Il'iushchenko. Minsk: NAN Belarusi, 2020, iss. 43, pp. 122–129.

2. Kryvanos A.K., Ilyushchanka A.Ph., Buloychik V.M. Modeling of structure formation of energy-saturated heterogeneous composite material. Journal of Physics: Con-ference Series, 2020, vol. 1507, p. 082037.

3. Naumenko A.M., Ryklin D.B. Modelirovanie gradienta nerovnoty smeshivaniia ideal'nykh dvukhkompo-nentnykh produktov [Modeling of the mixing roughness gradient of ideal two-component products]. Vestnik Viebskogo gosudarstvennogo tekhnologicheskogo universiteta, 2013, no. 25, pp. 42–49.

4. Liubimyi N.S. et al. Matematicheskoe opisanie protsessov okonchatel'-noi stadii smesheniia, prokhodiashchikh vo vneshnem kanale smesitel'noi kamery [Mathematical description of the processes of the final stage of mixing taking place in the external channel of the mixing chamber]. Izvestiia vuzov. Investitsii. Stroitel'stvo. Nedvizhimost', 2019, no. 9(3), pp. 530–541. DOI: 10.21285/2227-2917-2019-3-530-541

5. Mizonov V.E. et al. Teoreticheskoe issledovanie vliianiia parametrov smeshivaniia na vremia smeshivaniia i kachestvo smesi raz-norodnykh dispersnykh materialov [Theoretical study of the influence of mixing parameters on mixing time and quality of a mixture of heterogeneous disperse materials]. Vestnik IGEU, 2018, no. 5, pp. 56–61.

6. Il'iushchenko A.F. et al. Povyshenie plotnosti upakovki tverdoi fazy geterogennogo kompozitsionnogo materiala. Osnovnye problemy i puti ikh resheniia [Increase of packing density of solid phase of heterogeneous composite material. Main problems and ways of their solution] Poroshkovaia metallurgiia: sbornik nauchnyh trudov. Ed. A.F. Il'iushchenko. Minsk: NAN Belarusi, 2017, iss. 40, pp. 42–47.

7. Krivonos O.K. Obosnovanie sposobov issledovaniia protsessa smeshivaniia polidispersnykh poroshkov s nesferi­cheskoi formoi chastits v srede polimernogo sviazuiushchego [Justification of research methods of mixing polydisperse powders with nonspherical shape of particles in the medium of polymer binder]. Poroshkovaia metallurgiia: Inzheneriia poverkhnosti, novye poroshkovye kompozitsi­onnye materialy. Svarka: sbornik dokladov 13go Mezhdunarodnogo simpoziuma (Minsk, 5–7 aprelia 2023 g.). Ed. A.F. Il'iushchenko et al. Minsk: Belarus. navuka, 2023, pp. 338–348.

8. Il'iushchenko A.F., Krivonos O.K., Petiushik E.E. Sposob rascheta kolichestvenno-kachestvennykh kharakteri-stik poroshkovykh i zhidkofaznykh komponentov EGKM [Method of calculation of quantitative-qualitative characteristics of powder and liquid-phase EGCM components]. Poroshkovaia metallurgiia: sbornik nauchnyh trudov. Ed. A.F. Il'iushchenko et al. Minsk: NAN Belarusi, 2022, iss. 45, pp. 170–180.

9. Edvards R. Riady Fur'e v sovremennom izlozhenii [Fourier in a modern presentation]. Moscow: Mir, 1985, vol. 1, 264 p.

10. Chigireva O.Iu. Riady Fur'e. Preobrazovanie Fur'e: metodicheskie ukazaniia [Fourier transform: methodical instructions]. Ed. A.N. Kanatnikova. Moscow: Izdatelsyvo MGTU im. N.E. Baumana, 2010, 51 p.

11. Bat M. Spektral'nyi analiz v geofizike [Spectral analysis in geophysics]. Ed. V.N. Lisina, V.M. Kuznetsova. Moscow: Nedra, 1980, 535 p.

12. Marpl-ml. S.L. Tsifrovoi spektral'nyi analiz i ego prilozheniia [Digital spectral analysis and its applications]. Moscow: Mir, 1990, 584 p.

13. Prokhorov S.A., Grafkin V.V. Strukturno-spek­tral'­nyi analiz sluchainykh protsessov [Structure-spectral ana­lysis of random processes]. Samara: SNTs RAN, 2010, 128 p.

14. Dashenkov V.M. Spektral'nyi analiz i sintez signalov: laboratornoe posobie [Spectral analysis and synthesis of signals: laboratory manual]. Mn.: BGUIR, 2004, 20 p.

15. Pavleino M.A., Romadanov V.M. Spektral'nye preobrazovaniia v MATLAB: uchebno-metodicheskoe poso-bie [Spectral transformations in MATLAB: textbook]. Saint-Petersburg, 2007, 160 p.

16. Viner N., Peli R. Preobrazovanie Fur'e v kompleksnoi oblasti [Fourier transform in the complex domain]. Moscow: Nauka, 1964, 267 p.

17. Kharkevich A.A. Spektry i analiz [Spectra and analysis]. 4nd. Moscow: Gosudarstvennoe izdatelstvo tekh.-teor. literatury, 1957, 235 p.

18. Kryvanos A.K., Ilyushchanka A.Ph., Piatsiushyk Y.Y., Buloichyk V.M. Modeling and optimization of the structure of a highly filled polymer composite material in the process of mixing components. Deutsche internationale Zeitschrift für zeitgenössische Wissenschaft, 2021, no. 17, pp. 65–73. DOI: 10.24412/2701-8369-2021-17-65-73

19. Krivonos O.K. et al. Razrabotka matematicheskoi modeli strukturo-obrazovaniia energonasyshchennogo kom­po­zi­tsionnogo materiala [Development of mathematical model of structure formation of energy-rich composite material]. Polimernye materialy i tekhnologii: mezhdunarodnyi nauchno-tekhnicheskii zhurnal. Gomel': IMMS NAN Belarusi, 2021, vol. 7, no. 1, pp. 23–32.

20. Strenk F. Peremeshivanie i apparaty s meshalkami [Stirring and apparatus with stirrers]. Ed. Shchupliaka I.A.  Leningrad: Khimiia, 1975, 384 p.

21. Uilkinson U.L. Nen'iutonovskie zhidkosti. Gidro­mekhanika, peremeshivanie i teploobmen [Non-Newtonian fluids. Hydromechanics, mixing and heat exchange]. Ed. A.V. Lykova. Moscow: MIR, 1964, 216 p.

This paper presents the results of experimental investigations into the particle size distribution of the AlSi10Mg metal powder composition. Statistical control of the granulometric composition of two powder batches, sieved through meshes of 30 and 60 µm respectively, was conducted. An express analysis of the powder particle sizes was performed using images from two sievings obtained through Scanning Electron Microscopy (SEM). A software component for the express analysis of incoming inspection results for powder, using SEM images, was developed and a step-by-step scheme of the software component operation is provided. The express analysis of each of the two powder batches, obtained using the developed program, enables the visualization of the powder composition granule distribution by particle size, revealing a normal unimodal distribution. When increasing the mesh cell size from 30 to 60 µm, the mode of the powder particle size increases by approximately 10 µm (from 25.2 to 35.3 µm), and the 85th percentile from 29.3 to 57.4 µm. The presented results facilitate more confident experimental-technological work related to the direct synthesis of samples and the search for optimal parameters of the Selective Laser Melting process. An evaluation of the efficiency of the proposed software component compared to manual analysis of SEM images of the sieved powder material microstructure is provided. It is demonstrated that the use of express analysis tools allows for approximately a 24 % reduction in the incoming inspection time of powder material batches using the proposed methodology. Based on the research apparatus and methodology, a conclusion about the repeatability of the results for a larger sample is made. A conclusion about the possibility of using the proposed software component as an alternative for other incoming inspection methods (e.g., laser diffraction method) is drawn.

Keywords: additive manufacturing, incoming quality control, quality management, statistical distribution, SEM (Scanning Electron Microscopy), powder bed fusion, express analysis, metal powder composition, AlSi10Mg, technological process optimisation.

Veniamin A. Brykin (Moscow, Russian Federation) – Moscow Aviation Institute (National Research University).

Andrey V. Ripetsky (Moscow, Russian Federation) – Moscow Aviation Institute (National Research University).

Konstantin S. Korobov (Moscow, Russian Federation) – Moscow Aviation Institute (National Research University).

1.   Poltoran Ia.E., Vedishchev K.A. 3D-pechat' v sovremennoi promyshlennosti [3D printing in modern industry]. Alleia nauki, 2019, vol. 1, no. 7, pp. 3–6.

2.   Mironov D.R., Asylguzhin T.R., Skorynina S.E. Obzor rynka additivnykh tekhnologii [Intellectual property and innovation]. Intellektual'naia sobstvennost' i innovatsii, Ekaterinburg, 2018, pp. 132–137.

3.   Agrawal R. Sustainable design guidelines for additive manufacturing applications. Rapid Prototyping Journal,  2022.

4.   Elistratova A.A., Korshakevich I.S., Tikhonenko D.V. Tekhnologii 3D-pechati: preimushchestva i nedostatki [3D prin­ting technologies: advantages and disadvantages]. Aktual'nye pro­blemy aviatsii i kosmonavtiki, 2015, vol. 1, no. 11, pp. 557–559.

5.     Ignatov P.V., Pavlenko T.G. 3D-Printery. Pre-imu­shches­tva i nedostatki [3D Printers. Advantages and disadvantages]. Fizika i sovremennye tekhnologii v APK, 2020, pp. 38–41.

6.   Ford S., Despeisse M. Additive manufacturing and sustainability: an exploratory study of the advantages and challenges. Journal of cleaner Production, 2016, vol. 137, pp. 1573–1587.

7.   Rosenthal I., Stern A., Frage N. Microstructure and mechanical properties of AlSi10Mg parts produced by the laser beam additive manufacturing (AM) technology. Metal-logra­phy, Microstructure, and Analysis, 2014, vol. 3, pp. 448–453.

8.   Elisov V.P., Cherepanov D.V., Rykov A.D. 3D-Pechat' metallicheskimi poroshkami detalei RKT s pri-meneniem iacheistykh struktur [3D-Printing of RCT parts with metal powders using cellular structures]. Aktual'nye problemy aviatsii i kosmonavtiki, 2022, pp. 302–304.

9.   Slotwinski J.A. et al. Characterization of metal powders used for additive manufacturing. Journal of research of the National Institute of Standards and Technology, 2014, vol. 119, pp. 460.

10. Kniazev A.E., Vostrikov A.V. Rassev poroshkov v additivnom i granul'nom proizvodstvakh (obzor) [Powder sieving in additive and granule production (review)]. Trudy VIAM, 2020, no. 11 (93), pp. 11–20.

11. Ostrobrod B.E., Ostrobrod S.B., Novoselova T.V. Perspektivy primeneniia additivnykh tekhnologii [Prospects for the application of additive technologies]. Nauka i soremennost': materialy vserossiiskoi nauchno-prakticheskoi konferenysii. Ed. L.A. Svetlichnaia. Politekhnicheskii institut (filial) DGTU v g. Taganroge, 2022, pp. 22.

12. Nikiforov S.O., Pavlov A.N., Butukhanov V.A. Formirovanie ob"emnykh izdelii iz metallicheskikh po-roshkov 3D-printerom [Formation of volumetric products from metal powders by 3D printer]. Moscow, 2022.

13. Dadbakhsh S. et al. Influence of SLM on shape memory and compression behaviour of NiTi scaffolds. CIRP annals, 2015, vol. 64, no. 1, pp. 209–212.

14. Edelmann A., Dubis M., Hellmann R. Selective laser melting of patient individualized osteosynthesis plates – Digi-tal to physical process chain. Materials, 2020, vol. 13, no. 24, pp. 5786.

15. Hao L. et al. Design and additive manufacturing of cellular lattice structures. The International Conference on Advanced Research in Virtual and Rapid Prototyping (VRAP). Taylor & Francis Group, Leiria, 2011, pp. 249–254.

16. Abramov I.V., Lukina Iu.D., Abramov V.I. Obes-pechenie razvitiia additivnykh tekhnologii v Rossii v usloviiakh sanktsii [Ensuring the development of additive technologies in Russia in the context of sanctions]. Russian Economic Bulletin, 2022, vol. 5, no. 4, pp. 198–204.

17. Poliakov R.I., Sinitsyna E.I. Tekhnologiia 3D-pechati v usloviiakh importozameshcheniia [3D printing technology under conditions of import substitution]. Innovatsionnoe razvitie tekhniki i tekhnologii v promyshlennosti (INTEKS-2022), 2022, pp. 74–76.

18. Abramov I.V., Abramov V.I. Tsentry additivnykh tekhnologii – draivery tsifrovoi transformatsii ekonomiki [Additive Technology Centers - Drivers of Digital Transformation of the Economy]. Voprosy innovatsionnoi ekonomiki, 2022, vol. 12, no. 3.

19. Kniazev A.E. i dr. Issledovaniia tekhnologicheskikh svoistv metalloporoshkovykh kompozitsii titanovykh splavov VT6 i VT20, poluchennykh metodom induktsionnoi plavki i gazovoi atomizatsii [Studies of technological properties of metal-powder compositions of titanium alloys BT6 and BT20 obtained by induction melting and gas atomization method]. Trudy VIAM, 2017, no. 11 (59), pp. 44-53.

20. Popov V.V. et al. Powder bed fusion additive manufacturing using critical raw materials: A review. Materials, 2021, vol. 14, no. 4, pp. 909.

21. Sergeev A.N. et al. Realizatsiia sistemnogo podkhoda v kompleksnykh issledovaniiakh svoistv sovremennykh 1 materialov [Realization of system approach in complex researches of properties of modern 1 materials]. Razrabotka uchebno-metodicheskogo obespecheniia dlia vnedreniia innovatsionnykh metodov obucheniia pri realizatsii FGOS VO, 2018, pp. 352–357.

22. Strondl A. et al. Characterization and control of powder properties for additive manufacturing. Jom., 2015, vol. 67. – P. 549–554.

23. Sergeev A.N. et al. K voprosu optimizatsii vizualizatsii pri izuchenii novykh metallicheskikh materialov, poluchennykh tekhnologiei selektivnogo lazernogo spekaniia [To the question of visualization optimization in the study of new metallic materials produced by selective laser sintering technology]. Razrabotka uchebno-metodicheskogo obespecheniia dlia vne­dre­niia metodov obucheniia pri realizatsii FGOS VO, 2018, pp. 336–343.

24. Naim O.A.M., Ermakov D.N. The specifics of the development of additive manufacturing technologies in Russia in the context of globalization: economic and technological aspects. Journal of Positive School Psychology, 2023, pp. 71–82.

25. Abramov I.V., Abramov V.I. Perspektivy i problemy ispol'zovaniia additivnykh tekhnologii v Rossii v usloviiakh antirossiiskikh sanktsii [Prospects and problems of using additive technologies in Russia in the context of anti-Russian sanctions]. Tekhnika i tekhnologiia sovremennykh proizvodstv, 2022, pp. 3–7.

More than 80 % of machine parts are thrown away when worn, damaged or damaged, of which most can be restored by surfacing, spraying and other methods. At the same time, the cost of restoring a part is usually only 20–40 % of the cost of manufacturing a new part. Thus, the restoration of the wear surfaces of critical parts is an important production task, and the definition of an effective technology that ensures the restoration of parts according to the customer's conditions remains relevant in our time. The presented article discusses the technology of restoring plungers made of 40Kh steel using laser surfacing technology. Laser surfacing is a method of applying a material using a laser beam, which consists in applying a coating to the surface of the processed product by melting the base and filler material on the surface. The properties of the coating are determined mainly by the properties of the materials used for the coating. For steel, their properties are determined not only by the chemical composition, but also to a greater extent by changes in the structural and phase composition. The plunger material (40Kh steel) is prone to the formation of quenching structures. Based on the modeling of thermal processes and the prediction of phase transformations, it is shown that to reduce the probability of the formation of technological cracks, it is sufficient to heat the plunger at the site of the formation of a zone of thermal influence at 200...250 °C. Thermal processes and phase transformations during laser surfacing of steel, as well as the effect of phase transformations during rapid heating and cooling, are studied in this work. Microstructures and hardness, the presence of defects in the deposited layer in the products during their use are determined. The minimum heating temperature was determined to reduce the probability of formation of a martensitic structure during laser surfacing of the plunger using NH8M3C2 powder.

Keywords: laser surfacing, restoration of parts, hardening structures, heating temperature, cracks, heat affected zone, phase transformations, microstructure, hardness, martensitic structure, bainite structure.

Pavel Yu. Petrov (Moscow, Russian Federation) – Associate Professor, Associate Professor of the Department of Metal Technology of the NRU "MEI" (14, Krasnokazarmennaya str., Moscow, e-mail: PetrovPY@mpei.ru).

Regina V. Rodyakina (Moscow, Russian Federation) – Associate Professor, Associate Professor of Metals Technology Department of National Research University "MPEI" (14, Krasnokazarmennaya str., Moscow, e-mail: RodiakinaRV@mpei.ru).

Sergey A. Ovechnikov (Moscow, Russian Federation) – Senior Lecturer of the Department of Metal Technology of NRU "MEI" (14, Krasnokazarmennaya str., Moscow, e-mail: OvechnikovSA@mpei.ru).

Yue Jinqi (Taiyuan, China) – Taiyuan Research Institute of CCTEG-Xi'an Corporation, Researcher (Taiyuan, China e-mail: yuyejing1997@163.com).

Vasily S. Pichev (Moscow, Russian Federation) – Chief Technologist of JSC "Plakart" (19,
Simferopol highway, Shcherbinka, Moscow, e-mail: v.pichev@plakart.pro).

1. Panteleenko F.I., Lialiakin V.P., Ivanov V.P., Konstantinov V.M. Vosstanovlenie detalei mashin: spravochnik [Restoration of machine parts: reference book]. Ed. V.P. Iva­nova. Moscow: Mashinostroenie, 2003, 672 p.

2. Puchin E.A., Novikov V.S., Ochkovskii N.A. et al. Tekhnologiia remonta mashin [Machine repair technology]. Ed. E.A. Puchina. Moscow: KolosS, 2007, 488 p.

3. Chernoivanov V.I., Golubev I.G. Vosstanovlenie detalei mashin (Sostoianie i perspektivy) [Restoration of machine parts (Status and prospects)]. Moscow: FGNU «Rosinformagrotekh», 2010, 376 p.

4. Soboleva N.N. Povyshenie iznosostoikosti NiCrBSi pokrytii, formiruemykh gazoporoshkovoi lazernoi naplavkoi [Increase of wear resistance of NiCrBSi coatings formed by gas-powder laser cladding]. PhD. Thesis. Ekaterinburg, 2016,  24 p.

5. Cherepanov A.N., Orishich A.M., Ovcharenko V.E., Ma­li­kov A.G., Drozdov V.O., Pshenichnikov A.P. Vliianie na­no­modifitsiruiushchikh dobavok na svoi-stva mnogosloinogo kompozitsionnogo pokrytiia, polucha-emogo pri lazernoi na­plav­ke [Influence of nanomodifying additives on properties of multilayer composite coating produced by laser cladding]. Fizika metallov i metallovedenie, 2019, vol. 120, no. 1, pp. 107–112.

6. Perestoronin, A.V. Tekhnologiia lazernoi po-verkh­nostnoi modifikatsii bandazhnykh stalei karbidom vol'frama [Technology of laser surface modification of ban-dag steels with tungsten carbide]. PhD. Thesis. Moscow, 2019, 16 p.

7. Wang G., Fu Yu., Yao Q., Tong W. Steel layer on surface of low carbon steel. Heat Treatment of Metals, 2021, vol. 46, no. 2, pp. 38–43.

8. Ye S., Liu Jianyong, Yang W. Microstructure and properties of laser cladded 316L stainless steel layer. Surface Technology, 2018, vol. 47, no. 3, pp. 48–53.

9. Nekrasov R.Iu., Tempel' O.A., Starikov A.I. Opredelenie optimal'noi tolshchiny naplavki trudnoob-rabaty­vae­mogo materiala dlia vosstanovleniia rabotospo-sobnosti izdeliia [Determination of the optimal thickness of hard-to-machine material cladding for restoration of product operability]. Vestnik MGTU «Stankin», 2021, no. 2 (57), pp. 66–70.

10. Aleksandrova A.A., Bazaleeva K.O. Vliianie is-khodnogo sostoianiia poroshka na strukturu kompozitsion-nogo materiala Inkonel' 625/TIC, poluchennogo metodom lazernoi naplavki [Influence of initial powder state on the structure of Inconel 625/TIC composite material produced by laser cladding method]. Kliuchevye trendy v kompozitakh: nauka i tekhnologii: sbornik materialov Mezhdunarodnoi nauchno-prakticheskoi konferentsii, 2019, pp. 16–20.

11. Zubchenko A.S., Koloskov M.M., Kashirskii Iu.V. Marochnik stalei i splavov [Steel and Alloys Grade Book]. 2nd. Ed. A.S. Zubchenko. Moscow: Mashinostroenie, 2003, 784 p.

12. Mul' D.O. Poverkhnostnoe uprochnenie sredne-uglerodistoi khromistoi stali s ispol'zovaniem vneva-kuumnoi elektronno-luchevoi naplavki smesei poroshkovykh karbidoobrazuiushchikh materialov [Surface hardening of medium-carbon chromium steel using off-vacuum electron-beam cladding of powder carbide-forming material mixtures]. PhD. Thesis. Novosibirsk, 2015, 20 p.

13. Afanas'eva L.E., Ratkevich G.V. Lazernaia naplavka pokrytiia NiCrBSiFe – WC s pomoshch'iu mnogo-kanal'nogo lazera [Laser cladding of NiCrBSiFe - WC coating using a multichannel laser]. Letters on Materials, 2018, no. 8 (3), pp. 268–273.

14. Khomenko M.D. Sopriazhennye protsessy teplope-renosa, konvektsii i formirovaniia mikrostruktury pri lazernoi naplavke s koaksial'noi podachei metallicheskikh poroshkov [Coupled processes of heat transfer, convection and microstructure formation during laser cladding with coaxial feeding of metal powders]. Abstract of PhD. Thesis. Moscow, 2019, 18 p.

15. Sorokin V.G. et al. Stali i splavy. Marochnik: spravochnoe izdanie [Steels and alloys. Grade book: reference edition]. Ed. V.G. Sorokin, M.A. Gervas'ev. Moscow: Intermet Inzhiniring, 2001, 608 p.

16. Iue Ts., Petrov P.Iu. Issledovanie teplovykh protsessov pri lazernoi naplavke tsilindricheskoi detali [Study of thermal processes at laser cladding of cylindrical part]. Materialy mezhdunarodnoi nauchno-prakticheskoi on-lain-konferentsii «Mezhdistsiplinarnye issledovaniia nauki, tekhniki i obrazovaniia (NTO-1)».  Groznyi, 2023, pp. 170–175. DOI: 10.34708/GSTOU.2023.47.94.027

17. Petrov P.Iu., Iue Ts., Chepizubov I.G. Modeli-rovanie teplovykh protsessov pri vosstanovlenii tsilin-dricheskikh detalei [Modeling of thermal processes at restoration of cylindrical parts]. Naukosfera, 2022, no. 3 (1), pp. 143–148.

18. Petrov S.Iu. Analiz terminov i opredelenii, ispol'zuemykh v GOSTakh po svarke. Terminy: Svarnoe soedinenie, zona vliianiia i ee sostavnye chasti [Analysis of terms and definitions used in the State Welding Standards. Terms: Welded joint, influence zone and its components]. Svarochnoe proizvodstvo, 2017, no. 7, pp. 54–59.

19. Makarov E.L. Kholodnye treshchiny pri svarke legirovannykh stalei [Cold cracks in welding of alloy steels]. Moscow: Mashinostroenie, 1981, 247 p.

20. Volchenko V.N., Iampol'skii V.M., Vinokurov V.A. et al. Teoriia svarochnykh protsessov [Theory of welding processes]. Ed. V.V. Frolova. Moscow: Vysshaia shkola, 1988, 559 p.

21. Nekliudov A.N., Grigor'ev P.A., Troshko I.V. Osobennosti komp'iuternogo modelirovaniia strukturo-obrazo­va­niia na osnove ispol'zovaniia serii diagramm anizotermicheskogo raspada austenita [Peculiarities of computer modeling of structure formation on the basis of using a series of diagrams of anisothermal decomposition of austenite]. Nauchno-tekhnicheskii vestnik Brianskogo gosudarstvennogo universiteta, 2022, no. 4, pp. 348–356. DOI: 10.22281/2413-9920-2022-08-04-348-356

22. Lakhtin Iu.M., Leont'eva V.P. Materialovede-nie: uchebnik dlia mashinostroitel'nykh vuzov [Materials science: textbook for mechanical engineering universities]. 2nd. Moscow: Mashinostroenie, 1983, p. 155.

23. Popova L.E., Popov A.A. Diagrammy prevrashche-niia austenita v staliakh i beta-rastvora v splavakh titana: Sprav. Termista [Diagrams of austenite transformation in steels and beta-solution in titanium alloys: Terminologist's Reference.]. 3nd. Moscow: Metallurgiia, 1991, 500 p.

24. Abashkin E.E., Tkacheva A.V. Vliianie predvari-tel'nogo podogreva plastiny na znacheniia i raspredelenie ostatochnykh napriazhenii, obrazovannykh v rezul'tate naplavki [Effect of plate preheating on the values and distribution of residual stresses generated as a result of surfacing]. Morskie intellektual'nye tekhnologii, 2022, no. 3, chast' 1, pp. 310–318 DOI: 10.37220/MIT.2022.57.3.040

The phase composition, wear-resistant and adhesive properties of Zr1–хAlхN coatings formed by pulsed magnetron sputtering with a nitrogen content in the gas mixture N2=5–15 % have been studied. Based on a literature review, the phase transformations occurring in the Zr1–хAlхN system were analyzed depending on the Al content in it. At x≥0.5, a phase transition occurs in the Zr1–хAlхN system with a change in the cubic structure B1 (c-) (space group (s.g.) Fm m, prototype NaCl) to the hexagonal structure Bk (h-) (s.g. P63/mmc, prototype BN). At 0.43 ≤ x ≤ 0.73, a two-phase structure (c- + h-) is formed. When x exceeds ~0.68–0.73, preference is given to the hexagonal structure B4 (w-) (p.g. P63mc, prototype of ZnS-wurtzite). Diffraction patterns from areas of Zr1–хAlхN coatings were obtained on a Shimadzu XRD-6000 X-ray diffractometer in Cu-Kα radiation at a voltage of 30 kV and a current of 20 μA. The angular range was 2q = 300–800, the exposure time was 4 s per point. The structure and defectiveness of Zr1–хAlхN coatings were studied using a TESCAN VEGA3 (TESCAN, Czech Republic) scanning electron microscope (Oxford Instruments, UK). The wear-resistant and adhesive properties of the coatings were studied at room temperature using a REVETEST scratch tester adhesion meter (CSM Instruments, Switzerland). In the studied nitrogen range N2=5–15 %, three-phase coatings Zr1–xAlxN with 0.53£x£0.72 were formed based on orthorhombic о-Zr3N4, cubic с-Zr0,5Al0,5N and wurtzite w-AlN and и w-Zr0,5Al0,5N phases. The minimum friction coefficient and the minimum microhardness value correspond to the Zr0.28Al0.72N coating with the maximum amount of aluminum and the maximum volume fraction of wurtzite phases Vw-AlN+w-Zr0.5Al0.5N~54%. A decrease in the proportion of the thermally stable w-Zr0.5Al0.5N phase in the Zr1–xAlxN coating has a greater effect on the deterioration of its tribological properties.

Keywords: Zr1−xAlxN, pulsed magnetron sputtering, nitrogen content in the gas mixture, phase transition, elemental composition, structure, friction coefficient, critical load, indenter penetration depth into the coating, adhesive properties.

Anna L. Kameneva (Perm, Russian Federation) – Doctor of Technical Sciences, PhD, Department of Department of Innovative Engineering Technologies, Perm
National Research Polytechnic University (29, Komso­molsky av., Perm, 614990, Russian Federation, e-mail: annkam789@mail.ru).

Alexsander Yu. Klochkov (Perm, Russian Federation) – postgraduate student of the department Innovative technologies of mechanical engineering, Perm National
Research Polytechnic University (29, Komsomolsky
av., Perm, 614990, Russian Federation, e-mail: knv143@mail.ru).

1. Sanjinés R., Sandu C.S., Lamni R., Lévy F. Thermal decomposition of Zr1−xAlxN thin films deposited by magnetron sputtering. Surface & Coatings Technology, 2006, vol. 200, no. 22-23 SPEC. ISS, pp. 6308 –6312.

2. Makino Y., Mori M., Miyake S., Saito K., Asami K. Characterization of Zr–Al–N films synthesized by a magnetron sputtering method. Surface and Coatings Technology, 2005, vol. 193, no. 1–3, pp. 219-222.

3. Hasegawa H., Kawate M., Suzuki T. Effects of Al contents on microstructures of Cr1-XAlXN and Zr1-XAlXN films synthesized by cathodic arc method. Surf. Coat. Technol., 2005, vol. 200, no. 7, pp. 2409-2413.

4. Lamni R., Sanjinés R., Parlinska-Wojtan M., Karimi A., and Lévy F. Microstructure and nanohardness properties of Zr–Al–N and Zr–Cr–N thin films. Journal Vacuum Science Technology. A., 2005, vol. A 23, no. 4, pp. 593–598.

5. Sheng S.H., Zhang R.F., Veprek S. Phase stabilities and thermal decomposition in the Zr1-xAlxN system studied by ab initio calculation and thermodynamic modeling. Acta Materialia, 2008, vol. 56, no. 5, pp. 968–976.

6. Spillmann H., Willmott P., Morstein M., Uggowitzer P. ZrN, ZrxAlyN and ZrxGayN Thin films – novel materials for hard coatings grown using pulsed laser deposition. Appl. Phys. A., 2001, vol. 73, pp. 441-450.

7. Klostermann H., Fietzke H., Modes T., Zywitzki O. Zr-Al-N Nanocomposite Coatings Deposited by Pulse Magnetron Sputtering. Rev. Adv. Mater. Sci., 2007, iss. 15, pp. 33–37.

8. Lamni R., Sanjinés R., Lévy F. Electrical and optical properties of Zr1−xAlxN thin films. Thin Solid Films. 2005, vol. 478, pp. 170–175.

9. Kameneva A.L., Kichigin V.I., Bublik N.V. Effect of structure, phase, and elemental composition of AlN, CrAlN, and ZrAlN coatings on their electrochemical behavior in 3% NaCl solution. Materials and corrosion, 2022, vol. 73(8), pp. 1308–1317.

10. Kameneva A., Klochkov A., Kameneva N. Influence of the nitrogen content in the gas mixture on elemental composition of Zr1-xAlxN thin coating, its microhardness and friction coefficient. Materials Today: Proceedings, 2019, vol. 19, pp. 2549–2551.

11. Kuppusami P., Singh A., Mohandas E. Microstructural, Nanomechanical and Tribological Properties of ZrAIN Thin Films Prepared by Pulsed DC Magnetron Sputtering. Proceedings of the "International Conference on Advanced Nanomaterials and Emerging Engineering Technologies" (ICANMEET-20/3), organized by Sathyabama University, Chennai, India in association with DRDO, New Delhi, India, 24th-26th, July, 2013.

12. Ruan J.-L., Huang J.-L., Chen J.S., Lii D.-F. Zr–Al–N diffusion barrier films. Surf. Coat. Technol., 2005,
vol. 200, pp. 1652–1658.

13. Franz R., Lechthaler M., Polzer C., Mitterer C. Oxidation behaviour and tribological properties of arc-evaporated ZrAlN hard coatings. Surface & Coatings Technology, 2012, vol. 206, no. 8-9, pp. 2337–2345.

14. Antonova N.M., Babichev D.P., Dorofeev V.Y. Regularities of formation of the structure of Al-containing nanocomposites upon interaction of ASD-6 powder
with polymer suspension. Protection of Metals and
Physical Chemistry of Surfaces, 2013, vol. 49(7),
pp. 869–873.

15. Holec D., Rachbauer R., Chen L., Wang L., Luef D., Mayrhofer P.H. Phase stability and alloy-related trends in Ti–Al–N, Zr–Al–N and Hf–Al–N systems from first principles. Surf. Coat. Technol., 2011, vol. 206, pp.1698–1704.

16. Mayrhofer P. H., Sonnleitner D., Bartosik M., Holec, D. Structural and mechanical evolution of reactively and non-reactively sputtered Zr–Al–N thin films during annealing. Surface and Coatings Technology, 2014, vol. 244, pp. 52–56.

17. Makino Y. Application of Band Parameters to Materials Design. ISIJ International, 1998, vol. 38, no. 9, pp. 925-934.

18. Rogström L., Johnson L., Johansson M., Ahlgren M., Hultman L., Odén M. Thermal stability and mechanical properties of arc evaporated. ZrN/ZrAlN multilayers. Thin Solid Films, 2010, vol. 519, pp. 694-699.

19. Benia H., Guemmaz M., Schmerber G., Mosser A., Parlebas J.-C. Investigations on non-stoichiometric zirconium nitrides. Appl. Surf. Sci., 2002, vol. 200, pp. 231–238.

20. Chhowalla M., Unalan H.E. Thin films of hard cubic Zr3N4 stabilized by stress. Nat. Mater., 2005, vol. 1338, pp. 1–6.

21. Rogström L., Johnson L.J.S, Johansson M.P., Ahlgren M., Hultman L., Odén M. Age hardening in arc-evaporated ZrAlN thin films. Scripta Materialia, 2010, vol. 62, no. 10, pp. 739–741.

22. Ghafoor N., Johnson L.J.S., Klenov D.O., Demeulemeester J., Desjardins P., Petrov I., Hultman L., Odén M. Nanolabyrinthine ZrAlN thin films by self-organization of interwoven single- crystal cubic and hexagonal phases. APL Mater., 2013, vol. 1, no. 022105.

23. Kameneva A.L., Klochkov A.Iu. Vliianie davle-niia i sootnosheniia rabochikh gazov v gazovoi smesi na strukturu i mekhanicheskie svoistva Zr-Al-N pokrytiia [Influence of pressure and ratio of working gases in gas mixture on structure and mechanical properties of Zr-Al-N coating]. Materialy XXIV Ural'skoi shkoly metallovedov-termistov «Aktual'nye problemy fizicheskogo metallo-vedeniia stalei i splavov», g. Magnitogorsk, 19–23 marta, 2018 g. Magnitogorsk, 2018, pp. 149–152.

24. Kameneva A.L., Klochkov A.Iu., Kameneva N.V. Evoliutsiia elementnogo sostava, struktury i mikrotverdosti Zr-Al-N pokrytiia v usloviiakh izmeneniia sootnosheniia gazov v gazovoi smesi [Evolution of elemental composition, structure and micro-hardness of Zr-Al-N coating under conditions of changing the ratio of gases in the gas mixture]. Materialy mezhdunarodnoi nauchno-tekhnicheskoi konferentsii, posviashchennoi 85-letiiu so dnia rozhdeniia akademika V.N. Antsiferova, «Aktual'nye problemy poroshkovogo materialovedeniia», g. Perm', 26–28 noiabria, 2018 g. Perm', 2018, pp. 443–447.

25. Kameneva A.L., Klochkov A.Iu., Kameneva N.V. Osobennosti vliianiia fazovogo i elementnogo sostava iznosostoikogo i termodinamicheski ustoichivogo pokrytiia Zr-Al-N na ego mekhanicheskie i tribologicheskie svoistva [Features of influence of phase and elemental composition of wear-resistant and thermodynamically stable Zr-Al-N coating on its mechanical and tribological properties]. Sbornik trudov Mezhdunarodnogo nauchnogo simpo-ziuma tekhnologov – mashinostroitelei «Naukoemkie i vibrovolnovye tekhnologii obrabotki detalei vysoko-tekhnologichnykh izdelii», Rostov-na-Donu, 26-28 sentiab-ria, 2018 g. Rostov-na-Donu: Izdatelstvo DGTU, 2018, pp. 170–172.

An urgent task of modern mechanical engineering is theoretical modeling of the dependence of quality and accuracy parameters on modes of wire-cut EDM of products made of heat-resistant nickel alloys such as VV751P, development of empirical models describing the relationship between roughness and cut width of the machined surface of products. The aim of the work is a theoretical study of the peculiarities of the formation of quality and accuracy indicators at wire-cut EDM of products made of heat-resistant nickel alloy VV751P. To carry out the experiments, the material being processed was the heat-resistant nickel alloy VV751P. The wires were processed on an Electronica EcoCut wire-cut electrical discharge machine. To measure the roughness of the machined surface, a profilometer Pertometer S2, Mahr was used. An Olympus GX 51 light microscope was used to measure the cutting angle at 100x magnification. To obtain experimental data, a factory experiment was carried out. As a result of work performance regression dependences of roughness parameter and width of cut have been obtained. It is established that at h=10 mm the maximum value of roughness parameter Ra=3,155 microns is reached at Ton=30 µs, Toff=60 µs, the minimum value of roughness parameter Ra=1,15 microns at h=15 mm is reached at Toff=60 µs, Ton=21 µs. It was found that the maximum value of cutting width Y=380 µm is achieved at Ton=30 µs, Toff=60 µs, h=15 mm and the minimum value of cutting width Y=277 µm is achieved at Toff=51 µs, Ton=21 µs, h=15 mm.

Keywords: wire-cut EDM, heat-resistant nickel alloy VV751P, surface roughness, cutting width, regression analysis, factorial experiment, pulse on time, pulse off time, gas turbine engine product, granulated alloy.

Timur R. Ablyaz (Perm, Russian Federation) –
Candidate of Technical Sciences, Director of the Front Engineering School “Higher School of Aviation Engine Engineering” (29, Komsomolsky ave., Perm, 614990, e-mail: lowrider11-13-11@mail.ru).

Evgeniy S. Shlykov (Perm, Russian Federation) – Candidate of Technical Sciences, Associate Professor of the Department of High Technologies of Mechanical Engineering PNRPU (29, Komsomolsky ave., Perm, 614990,
e-mail: Kruspert@mail.ru).

Ilya V. Osinnikov (Perm, Russian Federation) – graduate student of the Department of High Technologies of Mechanical Engineering PNRPU (29, Kom­somolsky ave., Perm, 614990, e-mail: ilyuhaosinnikov@bk.ru).

Vladimir B. Blokhin (Perm, Russian Federation) – graduate student of the Department of Innovative
Technologies of Mechanical Engineering PNRPU
(29, Komso­molsky ave., Perm, 614990, e-mail: warkk98@mail.ru).

Vadim T. Khairulin (Perm, Russian Federation) –
chief engineer of UEC-Perm Motors (29, Komsomolsky ave., Perm, 614990, e-mail: khairulin-vt@mail.ru).

1. Jani J.M., Leary M., Subic A., Gibson M.A. A review of shape memory alloy research, applications and opportunities. Mater. Des., 2014, 56, 1078–1113. doi.org/10.1016/j.matdes.2013.11.084
2. Duerig T., Pelton A., Stöckel D. An overview of nitinol medical applications. Mater. Sci. Eng. A, 1999, 273, 149–160. doi.org/10.1016/S0921-5093(99)00294-4
3. Markopoulos A.P., Pressas I.S., Manolakos D.E. A Review on the machining of Nickel-Titanium shape memory alloys. Rev. Adv. Mater. Sci., 2015, 42, 28–35.
4. Stoeckel D. Shape memory actuators for automotive applications. Mater. Des. 1990, 11, 302–307.
5. Machado L.G., Savi M.A. Medical applications of shape memory alloys. Braz. J. Med. Biol. Res., 2003, 36, 683–691. doi: 10.1590/s0100-879x2003000600001
6. Garibov G.S. Teoriia kristallizatsii i tekhnologiia granuliruemykh zharoprochnykh nikelevykh splavov [Crytallization theory and technology of granulated heat-resistant nickel alloys]. Tekhnologiia legkikh splavov, 2016, no. 1, pp. 107–118.
7. Hassan M.R., Mehrpouya M., Dawood S. Review of the machining diculties of Nickel-Titanium based shape memory alloys. Appl. Mech. Mater., 2014, 564, 533–537. doi:10.4028/www.scientific.net/AMM.564.533
8. Jithin S., Joshi S.S. Surface Topography Generation and Simulation in Electrical Discharge Texturing: A Review. J. Mater. Process. Technol., 2021, 298, 117297. doi.org/10.1016/j.jmatprotec.2021.117297
9. Nowicki R., Świercz R., Oniszczuk-Świercz D., Dąbrowski L., Kopytowski A. Influence of Machining Parameters on Surface Texture and Material Removal Rate of Inconel 718 after Electrical Discharge Machining Assisted with Ultrasonic Vibration. In Proceedings of the AIP Conference Proceedings; AIP Publishing LLC: Melville, NY, USA, 2018, vol. 2017. doi:10.26628/wtr.v91i3.1042
10. Buk J. Surface Topography of Inconel 718 Alloy in Finishing WEDM. Adv. Sci. Technol. Res. J., 2022, 16, 47–61. doi.org/10.12913/22998624/142962
11. Rafaqat, M.; Mufti, N.A.; Ahmed, N.; Alahmari, A.M.; Hussain, A. EDM of D2 Steel: Performance Comparison of EDM Die Sinking Electrode Designs. Appl. Sci. 2020, 10, 7411. doi.org/10.3390/app10217411
12. Burek J., Babiarz R., Buk J., Sułkowicz P., Krupa K. The Accuracy of Finishing WEDM of Inconel 718 Turbine Disc Fir Tree Slots. Materials, 2021, 14, 562. doi.org/10.3390/ma14030562
13. Jithin S., Bhandarkar U.V., Joshi S.S. Three-Dimensional Topography Analysis of Electrical Discharge Textured SS304 Surfaces. J. Manuf. Process, 2020, 60, 384–399. doi.org/10.1016/j.jmapro.2020.10.066
14. Daneshmand S., Hessami R., Esfandiar, H. Investigation of wire electro discharge machining of Nickel-Titanium shape memory alloys on surface roughness and MRR. Life Sci., 2012, 9, 2904–2909. doi:10.1088/1757-899X/577/1/012078
15. Lotfi Neyestanak A.A., Daneshmand S. The effect of operational cutting parameters on Nitinol-60 in wire electrodischarge machining. Adv. Master Sci. Eng., 2013, 1–6. doi:10.1155/2013/457186
16. Sharma N., Raj T., Jangra K.K. Parameter optimization and experimental study on wire electrical discharge machining of porous Ni40Ti60 alloy. Proc. Inst. Mech. Eng. B J. Eng. Manuf., 2017, 231, 956–970. doi:10.1177/0954405415577710
17. Nowicki R., Świercz R., Oniszczuk-Świercz D., Rozenek M. Experimental Investigation of Technological Indicators and Surface Roughness of Hastelloy C-22 after Electrical Discharge Machining Using POCO Graphite Electrodes. Materials, 2022, 15, 5631. doi.org/10.3390/ma15165631
18. Tripathy S., Tripathy D. Multi-response optimization of machining process parameters for powder mixed electro-discharge machining of H-11 die steel using grey relational analysis and topsis. Mach. Sci. Technol., 2017, 21, 362–384. doi:10.1080/10910344.2017.1283957
19. Bisaria H., Shandilya P. Experimental studies on electrical discharge wire cutting of Ni-rich NiTi shape memory alloy. Mater. Manuf. Process, 2018, 33, 977–985. doi: 10.1080/10426914.2017.1388518
20. Khanna S., Utsav Patel R., Marathey P., Chaudari R., Vora J., Banerjee R., Ray A., Mukho­padhyay I. Growth of titanium dioxide nanorod over shape memory material using chemical vapor deposition for energy conversion application. Mater. Today Proc., 2020, 28, 475–479. doi:10.1016/j.matpr.2019.10.035
21. Safranski D., Dupont K., Gall K. Pseudoelastic NiTiNOL in Orthopaedic Applications. Shape Mem. Super­elasticity 2020, 6, 332–341. doi: 10.1007/s40830-020-00294-y
22. Chaudhari R., Vora J.J., Mani Prabu S.S., Palani I.A., Patel V.K., Parikh D.M., de Lacalle L.N.L. Multi-Response Optimization of WEDM Process Parameters for Machining of Superelastic Nitinol Shape-Memory Alloy Using a Heat-Transfer Search Algorithm. Materials, 2019, 12, 1277. doi.org/10.3390/ma12081277
23. Chaudhari R., Vora J.J., Patel V., Lacalle L.N.L.d., Parikh D.M. Effect of WEDM Process Parameters on Surface Morphology of Nitinol Shape Memory Alloy. Material, 2020, 13, 4943. doi.org/10.3390/ma13214943
24. Azam M., Jahanzaib M., Abbasi J.A., Abbas M., Wasim A., Hussain S. Parametric analysis of recast layer formation in wire-cut EDM of HSLA steel. Int. J. Adv. Manuf. Technol., 2016, 87, 713–722.
25. Newton T.R., Melkote S.N., Watkins T., Trejo R.M., Reister L. Investigation of the effect of process parameters on the formation and characteristics of recast layer in wire-EDM of Inconel 718. Mater. Sci. Eng. A, 2009, 513, 208–215.
26. Soni H., Sannayellappa N., Rangarasaiah R.M. An experimental study of influence of wire electro discharge machining parameters on surface integrity of TiNiCo shape memory alloy. J. Mater. Res., 2017, 32, 3100–3108.
27. Theisen W., Schuermann A. Electro discharge machining of nickel-titanium shape memory alloys. Mater. Sci. Eng. A, 2004, 378, 200–204.

The issues of reliability and durability of cyclically loaded parts, for the first time manufactured in the Russian Federation by the company of JSC "ELKAM-Neftemash", thin-walled API subsurface pumps, are considered. Authors described cases of fatigue failures of parts during operation in aggressive environments and cyclic loads, typical of downhole pumping submersible equipment. The stages of fatigue crack development are listed.

Authors analyzed in detail the advantages of induction heat treatment in various aspects: high performance, quickness of setup and input-output to the regime, energy efficiency, relatively low capital costs, minor thermal deformations, ecologically friendly, a wide possibility of automation and integration into technological chains.

The analysis of hardening mechanisms involved in induction heat treatment of cyclically loaded parts is carried out. Authors demonstrated the effectiveness of the considered hardening method, which locally implements all four known strengthening mechanisms. The implementation of each mechanism is explained.

Autors defined sizes for local hardening by induction heat treatment, including at least a machining allowance, static and cyclic plastic zones, that shown graphically on a 3D-model. At the paper are given formulas for hardening zones calculation.

For induction heat treatment, the target structure is substantiated – secondary sorbate or tempered troostite. Criteria for quality control are proposed: actual hardening depth; hardness of the material at the minimum depth of hardening; achievement of the target microstructure, as well as the methods and techniques of control.

It is shown that using the proposed mode and parameters of induction heat treatment of cyclically loaded parts from UNS 5140: quenching 900 °C in water, tempering 400 °C, the target microstructure, the corresponding stable hardness, and sufficient hardening depth are achieved. The results of control according to the established criteria in the form of macro- and microstructures, a graph of the local distribution of microhardness are given.

Keywords: induction heat treatment, heat treatment quality control, microstructure, macrostructure, local strengthening, cyclic loading, stress, thread hardening, run life, reliability, API thin wall pump, crack resistance, UNS 5140 steel, engineering technology.

Stanislav N. Moltsen (Perm, Russian Federation) – Head of quality service ELKAM, a postgraduate of Metals and heat treatment department, Perm National Research Polytechnic University (29, Komsomolsky ave., Perm, 614990, Russian Federation, e-mail: stanislav@vputehod.ru), NACE member, ORCID: 0000-0002-5269-8119

Ilona V. Shestakova (Perm, Russian Federation) – Student of of Metals and heat treatment department
(29, Komsomolsky ave., Perm, 614990, Russian Federation, e-mail: sestakovailona741@gmail.com).

Andrew V. Kravchenko (Perm, Russian Federation) – Deputy of head quality service ELKAM, a postgraduate of Metals and heat treatment department, Perm National Research Polytechnic University (29, Komsomolsky ave., Perm, 614990, Russian Federation, e-mail: stanislav@vputehod.ru), NACE member, ORCID: 0000-0003-4308-2977.

Yuri N. Simonov (Perm, Russian Federation) – Doctor of engineering science, professor, the head of Metals and heat treatment department, Perm National Research Polytechnic University (29, Komsomolsky ave., Perm, 614990, Russian Federation, e-mail: Simonov@pstu.ru).

1.   API 11AX13ed. Spetsifikatsiia ShGN, sboroch­nykh uzlov, komponentov i fittingov [Specification of the NGN, assemblies, components and fittings].
2.   Georgiev M.N., Simonov Iu.N. Treshchinostoi-kost' zhelezouglerodistykh splavov: monografiia [Crack resistance of iron-carbon alloys: monograph].  Perm': Izdatelstvo PNIPU, 2013.
3.   Simonov Iu.N., Georgiev M.N., Simonov M.Iu. Osnovy fiziki i mekhaniki razrusheniia: uchebnoe posobie dlia vuzov [Fundamentals of physics and fracture mechanics: textbook for universities]. Perm': Izdatelstvo PNIPU, 2012.
4.   Simonov Iu.N. Fizika prochnosti i mekhaniche-skie ispytaniia metallov [Physics of strength and mechanical testing of metals]. Perm': Izdatel'stvo PNI-PU, 2017.
5.   Shtremel' M.A. Razrushenie: v 2 knigah. Kniga 1. Raz­ru­shenie. Monograhfiia [Destruction: in 2 books Book 1: Destruction. monographs]. Moscow: Izdatelskii Dom MISiS, 2015, 976 p.
6.   GOST 31835-2012. Nasosy skvazhinnye shtango-vye. Obshchie tekhnicheskie trebovaniia [Downhole rod pumps. General technical requirements]. Moscow, 2012.
7.   Shigley J.E., Mischke C.R. Mechanical engineering design. 5nd. McGraw-Hill, New York, 1989, 123 p.
8.   Fatigue strength-load cycle relationships for ferrous material GU¨ LCAN TOKTAS¸ Department of Mechanical Engineering. Balikesir University, Balikesir, Turkey. Springer.
9.   Spravochnik metallista: 9 nd. Vol. 1. Svoistva i vybor zheleza i stalei [Metalworker's Handbook: 9 nd. Vol. 1. Properties and selection of iron and steels]. Amerikanskoe obshchestvo metallovedov, 1987, p. 67.
10. Tada H., Paris P.C., Irwin G.R. The stress analysis of cracks handbook. New York: ASME. 31. NACE, 2000.
11. GOST 31825-2012. Shtangi nasosnye, shtoki ust'evye i mufty k nim. Tekhnicheskie usloviia [Pump rods, wellhead rods and couplings to them. Technical specifications]. Moscow, 2012.
12. Atlas of fatigue curves, Edited by Howard E. Boyer Senior Technical Editor American Society for Metals, 1990, 534 p.
13. Heidersbach R. (Robert) Metallurgy and corro-sion control in oil and gas production. Published by John Wiley & Sons, Inc., 2011, 293 p.
14. Simonov Iu.N., Simonov M.Iu. Fizika proch-nosti i mekhanicheskie ispytaniia metallov: kurs lektsii [Physics of strength and mechanical testing of metals: a course of lectures]. Perm': Izdatelstvo Permskogo natsionalnogo issledovatelskogo politekhnicheskogo universiteta, 2020, 199 sp.
15. Materials science and engineering an introduction William D. Callister, Jr. Department of Metallurgical Engi-neering The University of Utah DAVID G. RETH-WISCH Department of Chemical and Biochemical Engineering The University of Iowa. Wiley, 2014, 1990 p.
16. Fraktografiia i atlas fraktogramm [Fractography and atlas of fractograms]. Ed.. E.A. Shura, M.L. Bernshteina. Moscow: Metallurgiia, 1982.
17. Kushnarenko V.M., Repiakh V.S., Chirkov E.Iu., Kushnarenko E.V. Defekty i povrezhdeniia detalei i konstruk-tsii: monografiia [Defects and damages of parts and structures: monograph]. Orenburg: OGU, 2011, 402 p.
18. Feargal Peter Brennan. Fatigue and fracture me-chanics analysis of threaded connections. Department of Mechanical Engineering University College London, 1992, 402 p.
19. Irwin G.R. Plastic zone near a crack and fracture toughness. Proc. 7th Sagamore Conf. Raquette Lake. New York, 1960, pp. IV-63.
20. Yokobori T. Fatigue crack propogation as succes-sive stochastic process. Report Research Inst. Strength Fract. Mater. Tohoku Univ., 1971, vol. 6, p. 18.
21. Nikiforov A.D. Tochnost' i tekhnologiia izgo-tovle­niia metricheskikh rez'b [Accuracy and manufacturing technology of metric threads]. Moscow: Vysshaia shkola, 1963, 181 p.
22. Popov A.A., Popova L.E. Izotermicheskie i termokineticheskie diagrammy raspada pereokhlazhdennogo austenita: Spravochnik termista [Isothermal and thermokinetic diagrams of decomposition of supercooled austenite: A thermologist's handbook]. 2nd. Moscow: Metallurgiia, 1965. 495 p.
23. Mol'tsen S.N., Kravchenko A.V., Simonov Iu.N., Polezhaev R.M. Povyshenie dolgovechnosti rez'bovykh soedi-nenii shtokov pri tsiklicheskoi nagruzke [Increase of durability of threaded rod connections under cyclic loading]. Vestnik Permskogo natsional'nogo issledovatel'skogo politekhnicheskogo universiteta. Mashinostroenie, materialovedenie, 2021, vol. 23, no. 2, pp. 27–35.
24. Kravchenko A.V., Mol'tsen S.N., Simonov Iu.N., Polezhaev R.M., Pogorelov E.V. Analiz i vybor metodov ispytaniia stalei na stoikost' k sul'fidnomu korrozionnomu rastreskivaniiu pod napriazheniem v H2S-soderzhashchikh sredakh [Analysis and selection of steel testing methods for resistance to stress sulfide corrosion cracking in H2S-containing media]. Vestnik Permskogo natsional'nogo issledovatel'skogo politekhnicheskogo unversiteta. Mashinostroenie, materialovedenie, 2021, vol. 23, no. 2, pp. 43-54.
25. Mol'tsen S.N., Kravchenko A.V., Simonov Iu.N., Polezhaev R.M. Garantiia kachestva cherez kontrol' kriticheskikh deviatsii mikrostruktury [Quality assurance through control of critical microstructure deviations]. Vest-nik Permskogo natsional'nogo issledovatel'skogo poli-tekhni­cheskogo universiteta. Mashinostroenie, materialo-vedenie, 2021, vol. 23, no. 1, pp. 36-45.
26. Mol'tsen S.N., Kravchenko A.V., Simonov Iu.N. Vliianie korrozionnykh povrezhdenii na rabotospo-sobnost' shtokov tonkostennykh shtangovykh nasosov. Mo-delirovanie i raschet [Influence of corrosion damage on serviceability of rods of thin-walled rod pumps. Modeling and calculation]. Vestnik PNIPU. Mashinostroenie. Materialovedenie, 2022, vol. 24, no. 1, pp. 5-14. DOI: 10.15593/2224-9877/2022.1.01
27. Gliaiter Kh., Khornbogen E. Uprochnenie pri ob-razovanii tverdykh rastvorov i dispersionnom tverdenii [Strengthening by solid solution formation and dis-percussion solidification]. Staticheskaia prochnost' i mekhanika razrusheniia stalei: sbornik nauchnyh tudov. Ed. V. Dalia, V. Antona. Moscow: Metallurgiia, 1986, 566 p.
28. ASM Handbook Volume 4C: Induction Heating and Heat Treatment, 2014, Editors: Valery Rudnev, George Totten. ASM International, 2014, 821 p.
 

Titanium alloys have a number of significant disadvantages in welding and surfacing technologies, such as heterogeneity and instability of the structure, a reduced level of mechanical properties, tensile strength, and loss of ductility, compared with the characteristics of standard semi-finished products of similar alloys. The article examines the possibility of using heat treatment to improve the structure and increase the mechanical properties of a material synthesized by layer-by-layer plasma surfacing from titanium alloys of the Ti-Al-V system. Particular attention was paid to studying the effect of heat treatment on strength during dynamic testing of the synthesized alloy for high-speed compression using the Kolsky method.

A mathematical model of the process of strengthening a deposited titanium alloy of the Ti-Al-V system under dynamic loading has been developed, based on the Johnson-Cook law approximation of deformation curves

The possibility of controlling the formation of the structure and properties of deposited layers during plasma additive surfacing in a chamber with a controlled atmosphere of an alloy of the Ti-Al-V system by changing the types of heat treatment is shown.

The optimal mode of heat treatment of an alloy of the Ti-Al-V system, obtained by plasma surfacing of wire material in a technological chamber with a controlled atmosphere of an inert gas, is complex heat treatment. The complex of mechanical properties of the deposited metal after optimized heat treatment provides a combination of strength and plastic properties at a sufficient level characteristic of metal of traditional technologies: a sufficiently high level of strength while maintaining impact toughness and ductility.

It was established that there is no significant effect of heat treatment on strength during dynamic tests of the synthesized alloy for high-speed compression using the Kolsky method: in the range of strain rates of 102−104 с–1, the ultimate strength remains at the level of 960–1000 MPa, characteristic of a material without heat treatment.

Keywords: titanium alloys, additive technologies, plasma surfacing, structure, dynamic tests, deformation curves, mechanical properties.

Albina V. Myshkina (Perm, Russian Federation) – senior lecturer, Department of Welding Production, Metrology and Technology of Materials, Perm National
Research Polytechnic University (29, Komsomolsky ave., Perm, 614990, Russian Federation, e-mail: albina_myshkina@mail.ru).

Svetlana N. Akulova (Perm, Russian Federation) – senior lecturer, Department of Welding Production,
Metrology and Technology of Materials, Perm National Research Polytechnic University (29, Komsomolsky
ave., Perm, 614990, Russian Federation, e-mail:
veta-ru@yandex.ru).

1. Vainerman A.E., Shorshorov M.Kh., Veselkov V.D., Novosadov V.S. Plazmennaia naplavka metallov [Plasma surfacing of metals]. Leningrad: Mashinostroenie, 1969, 191 p.

2. Shorshorov M.Kh., Meshcheriakov V.N. Fazo­vye prevrashcheniia i izmeneniia svoistv splavov titana pri svarke: atlas [Phase transformations and changes in properties of titanium-n alloys during welding: atlas]. Moscow: Nauka, 1973, 157 p.

3. Rykalin N.N., Uglov A.A., Anishchenko L.M. Vy-sokotemperaturnye tekhnologicheskie protsessy: Teplofi-zicheskie osnovy [High-temperature technological processes: Thermo-lophysical fundamentals]. Moscow: Nauka,
1986,  172 p.

4. Akulova S.N., Myshkina A.V., Khomutinin I.S., Krivonosova E.A., Liamin Ia.V. Issledovanie struktury i defektnosti  titanovykh splavov pri naplavke [Study of structure and defectivity of titanium alloys at cladding]. Vestnik Permskogo Natsional'nogo Issledovatel'skogo Politekhnicheskogo Universiteta. Mashinostroenie, Materialovedenie, 2022, vol. 24, no. 1, pp. 70–78.

5. Nochovnaia N.A., Antashev V.G., Shiriaev A.A., Alekseev E.B. Issledovanie vliianiia rezhimov izotermichesko-go deformirovaniia i termicheskoi obrabotki na struktu-ru i mekhanicheskie svoistva opytnogo zharoprochnogo Ti-splava [Investigation of the influence of modes of isothermal deformation and heat treatment on the structure and mechanical properties of experimental heat-resistant Ti alloys]. Tekhnologiia legkikh splavov, 2012, no. 4, pp. 92–98.

6. Liasotskaia V.S. Termicheskaia obrabotka svarnykh soedinenii titanovykh splavov [Heat treatment of welded joints of titanium alloys]. Moscow: EKOMET,
2003. 351 p.

7. Borisova E.A., Bochvar G.A. et al. Titanovye splavy. Metallografiia titanovykh splavov [Titanium alloys. Metallography of titanium alloys]. Moscow: Metallurgiia, 1980.

8. Illarionov A.G., Popov A.A. Tekhnologicheskie i ekspluatatsionnye svoistva titanovykh splavov: uchebnoe posobie [Technological and operational properties of titanium alloys: textbook]. Ekaterinburg: Ural'skii federal'nyi uni-versitet, EBS ASV, 2014. 136 p.

9. Perevalova O.B., Panin A.V., Siniakova E.A. Izmenenie fazovogo sostava i parametrov tverdogo rastvora na osnove α-Ti v poverkhnostnykh sloiakh splava Ti–6Al–4V, podvergnutogo elektronno-puchkovoi obrabotke [Change of phase composition and parameters of α-Ti-based solid solution in the surface layers of the alloy Ti-6Al-4V subjected to electron beam processing]. Fizika metallov i metallovedenie, 2020, vol. 121, no. 2, pp. 157–164.

10. Savchenko N.L. et al. Osobennosti strukturno-fazovogo sostoianiia splava Ti-6Al-4V pri formirovanii izdelii s ispol'zovaniem elektronno-luchevoi provolochnoi additivnoi tekhnologii [Features of structural-phase state of Ti-6Al-4V alloy at formation of products with use of electron-beam wire additive technology]. Obrabotka metallov: tekhnologiia, oborudovanie, instrumenty, 2018, vol. 20, no. 4, pp. 60–71.

11. Klimenov V.A. et al. Primenenie metodov fiziko-mekhanicheskikh issledovanii i metodov nerazrushaiushchego kontrolia pri razrabotke additivnykh tekhnologii s ispol'zovaniem titanovykh splavov [Application of physical and mechanical research methods and nondestructive testing methods in the development of additive technologies
using titanium alloys]. Fizicheskaia mezomekhanika materialov. Fizicheskie printsipy formirovaniia mnogourov­nevoi struktury i mekhanizmy nelineinogo povedeniia, 2022, pp. 430–431.

12. Nochovnaia N.A. et al. Issledovanie vliianiia rezhimov termicheskoi obrabotki na strukturu i mekhanicheskie svoistva osnov-nogo materiala i materiala svarnogo shva rabochikh koles tipa «blisk» iz splava VT41 v konstruktsii KVD per-spektivnogo dvigatelia [Study of influence of heat treatment modes on structure and mechanical properties of basic material and welded seam material of "blisk" type impellers made of VT41 alloy in the design of the FVD of a promising engine]. Elektrometallurgiia, 2017, no. 11, pp. 15–19.

13. Shchitsyn Y.D., Krivonosova E.A., Olshanska­ya T.V., Neulybin S.D. Structure and properties of aluminium magnesium scandium alloy resultant from the application of plasma welding with by-layer deformation hardening.
Tsvetnye Metally, 2020, no. 2, pp. 89–94. DOI 10.17580/tsm.2020.02.12.

14. Shchitsyn Y., Kartashev M., Krivonosova E., Olshanskaya T., Trushnikov D. Formation of structure and properties of two-phase Ti-6Al-4V alloy during cold metal transfer additive deposition with interpass forging. Ma-terials, 2021, vol. 14, no. 16. Art. 4415, 18 p. DOI 10.3390/ma14164415

15. Baiandin Iu.V. et al. Kharakteristiki prochnosti i plastichnosti ria-da metallicheskikh splavov i nerzhaveiu­shchikh stalei, sozdan-nykh provolochno-dugovoi naplavkoi, v shirokom diapa-zone skorostei deformatsii [Strength and ductility characteristics of a number of metal alloys and stainless steels created by wire-arc cladding in a wide range of strain rates]. Vestnik Permskogo natsional'nogo issledovatel'skogo politekhnicheskogo universiteta. Mekhanika, 2023, no. 1, pp. 33–45.

16. Akulova S.N., Myshkina A.V., Varushkin S.V., Neulybin S.D., Krivonosova E.A., Shchitsyn Iu.D., Ol'shanskaia T.V. O vliianii skhem plazmennoi naplavki na for-mirovanie struktury i svoistv titanovogo splava [On the influence of plasma cladding schemes on the formation of structure and properties of titanium alloys]. Vestnik Permskogo natsional'nogo issledovatel'skogo politekhnicheskogo universiteta. Mashinostroenie, Materialovedenie, 2021, vol. 23, no. 3, pp. 75–83.

17. Krivonosova E.A., Olshanskaya T.V., Akulova S.N., Myshkina A.V., Salomatova E.S.  Influence of the parameters of the heat treatment mode on the structure formation and properties of the welded material for the alloy Ti-Al-V. Journal of Physics: Conference Series, 2022,
vol. 2275, Art. 012010, 10 p.

18. Kolsky H. An investigation of the mechanical properties of materials at very high rates of loading.
Proceedings of the Physical Society. Section B.,
1949, vol. 62, no. 11, pp. 676–700. DOI:
10.1088/0370-1301/62/11/302

19. Kolsky H. Stress waves in solids. Journal of sound and Vibration, 1964, vol. 1, no. 1, pp. 88–110. DOI: 10.1016/0022-460X(64)90008-2

20. Johnson G.R., Cook W.H. A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. Proceedings of the 7th International Symposium on Ballistics. The Hague, Netherlands, 1983, vol. 21, pp. 541–547.

Additive technologies have a perspective place in the production of steel structures and are a high-performance alternative to traditional production in the creation of complex and large-sized details. One of the technologies of additive manufacturing is layer-by-layer surfacing using highly concentrated energy sources. Application of plasma surfacing with the use of combinations of technological methods allows to solve the issues of heterogeneity of structure in the volume of the surfaced layer and transcrystalline character of grain growth. The solution of these issues in the production of structures with the use of layer-by-layer surfacing remains relevant today. Control of thermal cycles in layer-by-layer surfacing, affecting crystallization processes, allows to improve the quality of the formed material.

The paper considers layer-by-layer plasma and plasma-MIG surfacing of austenitic class steels. The influence of thermal cycle of surfacing on the crystallization process and formation of the structure of the obtained material has been determined. The change of thermal cycle of surfacing for the investigated processes is established.  Significant differences in maximum heating temperatures and, accordingly, thermal cycles at the same form of melting at plasma surfacing and plasma-MIG surfacing have been revealed. It was found that the time of metal stay in the liquid state and cooling time from the maximum temperature to the crystallization temperature for both variants of surfacing differ insignificantly. The calculations confirmed that in plasma surfacing the crystallization process occurs at higher cooling rates than in plasma-MIG surfacing.

Keywords: plasma surfacing, thermal cycle, austenitic steels, additive manufacturing, crystallization front, temperature gradient, metal structure, crystallization, cooling rate, heat source.

Tatiana V. Olshanskaya (Perm, Russian Federation) – Doctor of Technical Sciences, Professor of the Department of Welding Production, Metrology and Materials Technology, Perm National Research Polytechnic University (29, Komsomolsky Ave., Perm, 614990, Russian Federation, e-mail: tvo66@rambler.ru).

Elena M. Fedoseeva (Perm, Russian Federation) – Candidate of Technical Sciences, Associate Professor of the Department of Welding Production, Metrology and Materials Technology, Perm National Research Polytechnic University (29, Komsomolsky Ave., Perm, 614990, Russian Federation, e-mail: emfedoseeva@pstu.ru).

Yury D. Shchitsyn (Perm, Russian Federation) – Doctor of Technical Sciences, Head of the Department of Welding Production, Metrology and Technology of Materials, Perm National Research Polytechnic University (29, Komsomolsky Ave., Perm, 614990, Russian Federation, e-mail: schicin@pstu.ru).

Alyona Yu. Dushina (Perm, Russian Federation) – Candidate of Technical Sciences, Associate Professor of the Department of Welding Production, Metrology and Materials Technology, Perm National Research Polytechnic University (29, Komsomolsky Ave., Perm, 614990, Russian Federation, e-mail: alena@pstu.ru).

1. Dushina A.Iu. Posloinaia plazmennaia naplavka stalei austenitnogo klassa tipa 308LSi  dlia additivnogo proizvodstva [Layer-by-layer plasma cladding of 308LSi type austenitic grade steels for additive manufacturing]. Abstract of PhD. thesis. Perm', 2022, 16 p.

2. Oskolkov A.A., Matveev E.V., Bezukladnikov I.I. et al. Peredovye tekhnologii additivnogo proizvodstva metallicheskikh izdelii [Advanced technologies for additive manufacturing of metallic products]. Vestnik Permskogo natsio-nal'nogo issledovatel'skogo politekhnicheskogo universiteta. Mashinostroenie, materialovedenie, 2018, vol. 20, no. 3, pp. 90–105. DOI 10.15593/2224-9877/2018.3.11

3. Chumakov D.M. Perspektivy ispol'zovaniia addi-tivnykh tekhnologii pri sozdanii aviatsionnoi i raketno-kosmicheskoi tekhniki [Prospects for the use of additive technologies in the creation of aviation and rocket-space equipment]. Trudy MAI, 2014, no. 78, pp. 31.

4. Zrazhevskii A.V. Primenenie additivnykh tekhno-logii v promyshlennosti [Application of additive technologies in industry]. Naukosfera, 2021, no. 8-1, pp. 9–13.

5. Rudskoi A.I., Popovich A.A., Grigor'ev A.V., Kaledina D.E. Additivnye tekhnologii [Additive technologies]. Sankt-Peterburgskii politekhnicheskii universitet Petra Ve-likogo, 2017, 252 p.

6. Herzog D. et al. Additive manufacturing of metals. Acta Materialia, 2016, vol. 117, pp. 371–392.

7. Mukherjee T. et al. Printability of alloys for additive manufacturing. Scientific reports, 2016, vol. 6, no. 1, pp. 1–8.

8. Tumbleston J.R. et al. Continuous liquid interface production of 3D objects. Science, 2015, vol. 347, no. 6228, pp. 1349–1352.

9. Dushina A.Iu. Posloinaia plazmennaia naplavka stalei austenitnogo klassa tipa 308lSi dlia additivnogo proizvodstva [Layer-by-layer plasma cladding of 308lSi austenitic grade steels for additive manufacturing]. PhD. Thesis. Perm', 2023, 148 p.

10. Rykalin N.N. Raschety teplovykh protsessov pri svarke [Calculations of thermal processes during welding]. Moscow: Izdatelstvo MAShGIZ, 1951, 296 p.

11. Terent'ev S.A. Razrabotka tekhnologii i oboru-dovaniia additivnogo proizvodstva metallicheskikh izdelii plazmennoi naplavkoi plaviashchimsia elektrodom [Development of technology and equipment for additive manufacturing of metal products by plasma cladding with a melting electrode]. Abstract of PhD. thesis. Perm', 2019, 16 p.

12. Terent'ev S.A. Razrabotka tekhnologii i oboru-dovaniia additivnogo proizvodstva metallicheskikh izdelii plazmennoi naplavkoi plaviashchimsia elektrodom [Разработка технологии и оборудования аддитивного производства металлических изделий плазменной наплавкой плавящимся электродом]. PhD.thesis. Perm', 2019.

13. Neulybin S.D. Vliianie poliarnosti toka na svoistva sloistykh materialov, poluchaemykh mnogosloinoi plazmennoi naplavkoi [Effect of current polarity on the properties of layered materials produced by multilayer plasma surfacing]. PhD. Thesis. Perm', 2017, 135 p.

14. Shchitsyn Iu.D. Spetsial'nye plazmennye tekhno-logii: uchebnoe Posobie [Special plasma technologies: textbook]. Perm': Izdatelstvo Permskogo natsionalnogo issledovatelskogo politekhnicheskogo universiteta, 2017, 159 p.

15. Shchitsyn Iu.D., Kosolapov O.A., Shchitsyn V.Iu. Vozmozhnosti plazmennoi obrabotki metallov tokom obratnoi poliarnosti [Possibilities of plasma treatment of metals with reverse polarity current]. Svarka. Diagnostika, 2009, no. 2, pp. 42–45.

16. Iazovskikh, V.M. Matematicheskoe modelirovanie i inzhenernye metody rascheta v svarke: v 2 chastiah. Chast 2. Teplovye protsessy pri svarke i modelirovanie v pakete MathCad [Mathematical modeling and engineering methods of calculation in welding: in 2 parts. Part 2: Thermal Processes in Welding and Modeling in MathCad Package]. Perm': Izdatelstvo PGTU, 2008, 119 p.

17. Iazovskikh, V.M. Matematicheskoe modelirovanie i inzhenernye metody rascheta v svarke: v 2 chastiah. Chast. 1. Statisticheskaia obrabotka i planirovanie eksperimenta [Mathematical modeling and engineering methods of calculation in welding: in 2 parts. Pate 1. Statistical processing and planning of experiment]. Perm': Izdatelstvo PGTU, 2007, 119 p.

18. Ol'shanskaia T.V., Fedoseeva E.M. Matematiche-skii analiz rosta nemetallicheskikh vkliuchenii v svaroch-noi vanne [Mathematical analysis of growth of non-metallic inclusions in the weld pool]. Vestnik Permskogo natsional'nogo issledo-vatel'skogo politekhnicheskogo universiteta. Mashinostroenie, materialovedenie, 2017, vol. 19, no. 1,
pp. 139–154.

19. Ol'shanskaia T.V., Fedoseeva E.M. Vybor os-novnykh kriteriev termicheskogo tsikla dlia metodov pro-gnozirovaniia struktury svarnykh shvov pri elektronno-luchevoi svarke [Selection of basic thermal cycle criteria for weld structure prediction methods for electron beam welding]. Vestnik Permskogo natsional'nogo issledovatel'skogo politekhnicheskogo universiteta. Mashinostroenie, materialovedenie, 2019, vol. 21, no. 2, pp. 73–81.

20. Fedoseeva E.M., Ol'shanskaia T.V., Dushina A.Iu. Zakonomernosti formirovaniia struktury v mekha-nizmakh kristallizatsii austenitnykh stalei (obzor) [Regularities of structure formation in crystallization mechanisms of austenitic steels (review)]. Vestnik PNIPU. Mashinostroenie. Materialovedenie, 2023, vol. 25, no. 1, pp. 83–97.

21. Dushina A.Iu., Karabatova U.A., Ol'shanskaia T.V., Fedoseeva E.M. Osobennosti kristallizatsii austenitnykh sta-lei pri additivnom proizvodstve [Peculiarities of crystallization of austenitic steels during additive manufacturing]. Khimiia, ekologiia, urbanistika, 2020, vol. 1,
pp. 324–328.

22. Olshanskaya T., Trushnikov D., Dushina A., Ganeev A., Polyakov A., Semenova I. Microstructure and Properties of the 308LSi Aus-tenitic Steel Produced by Plasma-MIG Deposition Welding with Layer-by-Layer Peening. Metals, 2022, vol. 12, iss. 1, Art. 82, 14 p.

23. Olshanskaya T.V., Dushina A.Y., Trushnikov D.N. Research of the technological methods influence on the for-mation of structure and properties during the additive growth of products from nickel chromium steels of the austenitic class by plasmajet hard facing methods. Journal of Physics: Con-ference Series. IOP Publishing, 2022, vol. 2275, no. 1, pp. 012003.

The article considers the influence of various hardening methods on the fatigue limit, geometry and surface layer of gas turbine engine blades.

At the moment, hydro-shot peening is the most widely used in the aircraft engine industry. This method creates a favorable diagram of residual stresses on the surface of the blade airfoil and makes it possible to increase the endurance limit by 19%. However, the depth of compressive residual stresses with this hardening method is up to 0.3 mm, which is not enough to provide the required level of fatigue strength of the blades in case of damage to the edges of the "nick" type from the ingress of foreign objects to a depth of 1 mm.

To increase the resistance of the blades to the ingress of foreign objects, 2 promising hardening methods are considered: laser impact hardening and low-plastic burnishing. To evaluate the effectiveness of each method, an object was chosen – a titanium blade 1 of the compressor stage of a gas turbine engine. The blade edge zone 5 mm wide was subjected to laser impact hardening (LSP, LSPwC) and low-plastic burnishing. After hardening, some of the blades were subjected to imitations of damage of the “nick” type of various depths and their endurance limit was determined. Hardening LSP and low-plastic burnishing meet the requirements of design documentation for roughness. The depth of compressive residual stresses during LSP and burnishing is more than 0.3 mm, which is superior to hydroblasting.

Edge hardening by all methods led to a decrease in the endurance limit of blades without concentrators by 9.3¸15.7% compared to blades without hardening. Hardening of the edges leads to an increase in the endurance limit for blades with a dent depth of 0.5 mm by 22.2¸31.4%, and for nicks with a depth of 1.0 mm – by 8.3¸14.8%, compared to blades without hardening with appropriate nicks.

Keywords: laser, laser impact, hardening, roughness, residual stresses, fatigue, low-plastic burnishing, titanium alloys, fatigue, hydroblasting

Alexey A. Shiryaev (Perm, Russian Federation) – Engineer КО-2993, JSC UEC-Aviadvigatel (93, Komsomolsky ave., Perm, 614990, Russian Federation,
e-mail: alex_sh_23-1@mail.ru).

Ivan G. Gabov (Perm, Russian Federation) – Department head 299, JSC UEC-Aviadvigatel (93, Komsomolsky ave., Perm, 614990, Russian Federation, e-mail: gabov-ig@avid.ru).

Artem S. Milenin (Perm, Russian Federation) – Department head КО-2993, JSC UEC-Aviadvigatel (93, Komsomolsky ave., Perm, 614990, Russian Federation,
e-mail: milenin-as@avid.ru).

Denis F. Tairov (Perm, Russian Federation) – Head of the brigade of KO-2993, JSC UEC-Aviadvigatel (93, Komsomolsky ave., Perm, 614990, Russian Federation,
e-mail: tairov@avid.ru).

1.   Sulima A.M., Shulov V.A., Iagodkin Iu.D. Poverkhnostnyi sloi i ekspluatatsionnye svoistva detalei mashin [Surface layer and performance properties of machine parts]. Moscow: Mashinostroenie, 1988, 240 p.

2.   Shvedova A.S. Povyshenie ekspluatatsionnykh svoistv detalei pri obrabotke dinamicheskimi metodami poverkhnostnogo plasticheskogo deformirovaniia [Increase of operational properties of parts during machining by dynamic methods of surface plastic deformation]. Vestnik DGTU, 2015, no. 1(80), pp. 114–120.

3.   Pavlov V.F., Kirpichev V.A., Vakuliuk V.S. Pro­gnozirovanie soprotivleniia ustalosti poverkhnostno uproch­nennykh detalei po ostatochnym napriazheniiam [Prediction of fatigue resistance of surface hardened parts by residual stresses]. Samara: Izdatelstvo SNTs RAN, 2012, 125 p.

4.   Pavlov V.F., Kirpichev V.A., Vasiliuk V.S., Sazanov V.P., Shliapnikov P.A. Vliianie gidrodrobestruinoi obrabotki na predel vynoslivosti obraztsov s nadrezom pri izgibe i rastiazhenii-szhatii [Effect of hydroblasting on the bending and tension-compression endurance of notched specimens]. Dinamika i vibroakustika, 2020, vol. 6, no. 1, pp. 25–34. DOI: 10.18287/2409-4579-2020-6-1-25-34

5.   Pavlov V.F., Sazanov V.P., Vakuliuk V.S. K vo-prosu otsenki vliianiia gidrodrobestruinoi obrabotki na predel vynoslivosti detalei po pervonachal'nym defor-matsiiam [Evaluation of the influence of hydroblasting on the endurance limit of parts based on initial deformations]. Vestnik PNIPU. Mashinostroenie, materialovedenie, 2019, vol. 21, no. 1, pp. 55–62. DOI: 10.15593/2224-9877/2019.1.08

6. Pavlov V.F., Vasiliuk V.S., Kirpichev V.A., Sazanov V.P., Dekan' A.A., Semenova O.Iu. Vliianie gidrodrobestruinoi obrabotki na pre-del vynoslivosti obraztsov razlichnogo diametra iz stali 45 [Influence of hydroblasting on the endurance limit of specimens of different diameters made of steel 45]. Innovatsionnye napravleniia integratsii nauki, obrazovaniia i proizvodstva, Kerch', 2022, pp. 85–89.

7.   Al'bov I.I., Burnashov M.A. Uprochnenie po-verkhnostei vodoledianymi struiami vysokogo davleniia [Surface hardening with high-pressure ice jets]. Fundamental'nye i prikladnye problemy tekhniki i tekhnologii, 2011, no. 2/3 (286), pp. 76–78.

8.   Miftakhov A.A., Mazein P.G. Modelirovanie ostatochnykh napriazhenii pri gidrodrobestruinoi obrabotke [Modeling of residual stresses during hydro-blasting operations]. Izvestiia Cheliabinskogo nauchnogo tsentra, 2006, no. 4(34), pp. 38–42.

9.   Petrosov V.V. Gidrodrobestruinoe uprochnenie detalei i instrumenta [Hydroblast peening of parts and tools]. Moscow, 1977, 168 p.

10. Odintsov L.G. Uprochnenie i otdelka detalei poverkhnostnym plasticheskim deformirovaniem: spravochnik [Strengthening and finishing of parts by surface plastic deformation: reference book.]. Moscow: Mashinostroenie, 1987, 328 p.

11. Sinchurin D.V. Vliianie metoda gidrodrobes-trui­nogo uprochneniia na povyshenie ekspluatatsionnoi nadezhnosti detalei [Influence of hydroblast peening method on increasing operational reliability of parts], 2015, no. 21.2 (101.2), pp. 54–57.

12. Gidrodrobestruinyi metod uprochneniia deta-lei GTD osnovannyi na plasticheskom deformirovanii poverkhnostnogo sloia [Elektronnyi resurs]. [Hydrodroblast method of hardening of GTE parts based on plastic deformation of the surface layer [Electronic resource]]. URL: https://www.gidroabraziv.com/technology/gidrodrobestrujnyj-metod-uprochneniya-detalej-gtd/ (data avalable 10.09.2021).

13. Liakhovetskii M.A., Korolev D.D., Kozhevnikov G.D., Volkov M.V. Lazernoe udarnoe uprochnenie titanovogo spla-va VT6 s aliuminievym abliatsionnym pokrytiem [Laser shock hardening of titanium alloy VT6 with aluminum ablation coating]. Bystrozakalennye materialy i pokrytiia: sbornik statei. Moscow, 2021, pp. 258–263.

14. Keller S., Chupakhin S., Staron P., Maawad E., Kashaev N., Klusemann B. Experimental and numerical investigation of resid-ual stresses in laser shock peened AA2198. Journal of Materials Processing Tech., 2018, vol. 255, pp. 294–307.

15. Ebrahimi M., Amini S., Seyed M. The investiga-tion of laser shock peening effects on corrosion and hardness properties of ANSI 316L stainless steel. Int J Adv Manuf Technol., 2017, no. 88, pp. 1557–1565. DOI: 10.1007/s00170-016-8873-0

16. Gorunov A.I., Gil'mutdinov A.Kh. Uprochnenie i naplavka volokonnym lazerom kak sposoby tselenaprav-lennogo formirovaniia struktury i svoistv titanovogo splava VT6 [ Strengthening and cladding by fiber laser as methods of purposeful formation of structure and properties of titanium alloy BT6]. Izvestiia vuzov. Poroshkovaia metallurgiia i funktsional'nye pokrytiia, 2015, no. 4, pp. 40–44. DOI: 10.17073/1997-308X-2015-4-40-44

17. Murataev F.I., Klabukov M.A. Osobennosti lazernogo udarnogo uprochneniia stalei i titanovykh splavov [Features of laser shock hardening of steels and titanium alloys]. Vestnik KGTU im. A.N. Tupoleva, 2012, no. 4, iss. 2, pp. 82–84.

18. Sundar    R., Ganesh P., Swati Maravi, Pushpendra K. Dwivedi, Ram K.G., Nagpure D.C., Ranganathan K., Abhijit C., Bindra K.S., Kaul R. Study on effect of laser shock peening as a pre-treatment on fatigue performance of hard-chorme plated 15–5 PH stainless steel. Lasers in Manufacturing and Materials Processing, 2019, no. 6, pp. 85–97. DOI:10.1007/s40516-019-0082-x

19. Kumar G.R., Rajyalakshmi G., Swaroop S., Stango S.A.X., Vijayalakshmi U. Laser shock peening wavelength conditions for en-hancing corrosion behaviour of titanium alloy in chloride environment. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2019, no. 41, p. 129. DOI:10.1007/s40430-019-1633-y

20. Sundar R., Ganesh P., Ram K.G., Ragvendra G., Pant B.K., Vivekanand K., Ranganathan K., Rakesh K., Bindra K.S. Laser Shock Peening and its Applications: A Re-view. Lasers in Manufacturing and Materials Processing, 2019, no. 6, pp.424–463. DOI:10.1007/s40516-019-00098-8

21. Jiang X.P., Man C.S., Shepard M.J., Zhai T. Effects of shot-peening and reshot-peening on four-pointbend fatigue behavior of Ti–6Al–4V. Mat Sci and Engg A., 2007, no. 468, pp. 137–143.

22. Altenberger I., Nalla R.K., Sano Y. On the effect of deep-rolling and laser peening on the stress-controlled low and high cycle fatigue behavior of Ti–6Al–4V at elevated temperatures up to 550 °C. Int J Fatigue., 2012, no. 44, pp. 292–302.

23. Shiganov I.N., Mel'nikov D.M., M'iat Z.I. Lazernoe udarnoe uprochnenie aliuminievykh materialov [Laser shock hardening of aluminum materials]. Lazery v nauke, tekhnike, meditsine: sbornik statei, Moscow, 2017, vol. 28, pp. 43–47.

24. Plekhov O.A., Kostina A.A., Iziumov R.I., Iziumova A.Iu. Konechno-elementnyi analiz ostatochnykh napriazhenii, voznikaiushchikh v rezul'tate lazernoi udarnoi prokovki titanovogo splava VT6 [Finite element analysis of residual stresses resulting from laser shock forging of titanium alloy BT6]. Vychislitel'naia mekhanika sploshnykh sred, 2022, vol. 15, no. 2, pp. 171–184.

25. Sikhamov R.A., Fomin F., Keller Z., Kashaev N. Modelirovanie ostatochnykh napriazhenii, so-zdannykh metodom lazernogo udarnogo uprochneniia [Modeling of residual stresses co-created by laser shock hardening method]. Nauchno-prakticheskii elektronnyi zhurnal Alleia Nauki, 2019, vol. 2, no. 6, pp. 18–25.

26. Sakhvadze G.Zh. Simulation of the technology of laser-shock-wave processing of titanium alloys with shape memory using dimensional analysis. Journal of Machinery Manufacture and Reliability, 2021, vol. 50, no. 4, pp. 332–341.

27. Sano Y., Akita K., Masaki K., Ochi Y., Alterberg I., Schoites B. Laser peening without coating as a surface en-hancement technology. Pulse, 2006, no. 100(40).

28. Guiba A.K., Medraj M. Laser peening process and its impact on materials properties in comparison with shot peening and ultrasonic impact peening. Materials, 2014, no. 7(12), pp. 7925–7974.