Translation. Region: Russian Federal
Source: Novosibirsk State University –
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Employees Competence Center of the National Technology Initiative (NTI) in the direction of "Modeling and development of new functional materials with specified properties" based at NSU developed an innovative method for restoring damaged turbine blades of engines for aviation and energy (gas turbine units). The technology was developed with financial support from the NTI Foundation, successfully patented and is already beginning to be implemented in practice.
Leading researcher of the NTI Center of Novosibirsk State University, head of the laser technology laboratory of the Institute of Theoretical and Applied Mechanics of the Siberian Branch of the Russian Academy of Sciences, Doctor of Engineering Alexander Malikov spoke in detail about the essence of the development and the prospects for its implementation:
— Our new method allows us to restore heavily worn sections of gas turbine blades, fully preserving the original performance characteristics of the product. To do this, we use a special mode of laser pulse-periodic action, which allows us to form strong protective layers of metal or ceramic composites on the surface.
According to Alexander Malikov, the task was to restore the thin edges of the blades, which are subject to intense exposure to high temperatures and pressure during engine operation. The advantage of the proposed technology is that using the traditional surfacing method would lead to overheating and destruction of sensitive areas of the parts.
"We proposed an original solution to the problem by preliminary forming special protective layers before the main stage of surfacing. This approach allowed us to preserve the original geometric shape of the blade and ensure reliable adhesion of the restored layer to the main structure," the scientist explained.
The new method significantly reduces the cost of repairs, ensuring high strength and durability of restored elements of gas turbine units.
The developed technology is in high demand on the Russian energy generation and aircraft manufacturing market. Modern gas turbine engines are used everywhere – from civil aviation to electric power engineering and natural gas transportation.
Alexander Malikov noted the importance of this area of research:
— The production of high-quality blades is one of the ten key technologies of the modern world. Their production requires complex solutions due to extreme operating conditions. Only four countries in the world have the necessary competencies: the USA, Great Britain, France and Russia.
Previously, the energy segment of the Russian market was heavily dependent on foreign suppliers of spare parts and services for the restoration of parts. With the departure of Western companies from the Russian market, there was a need to develop our own technologies and services capable of replacing foreign analogues. The new technology created by Novosibirsk scientists is capable of significantly increasing the reliability and cost-effectiveness of servicing large industrial enterprises and facilities using gas turbine units.
In the near future, it is planned to introduce the technology into serial production; a number of Russian companies have shown interest in it. Meanwhile, researchers continue to develop technologies for the restoration of various types of blades and other elements of industrial equipment.
— To solve problems of this type, we first need to carefully study the properties of the material from which the product is made at the atomic level. In our work, we use synchrotron radiation, which provides great opportunities for emitting phase composition at a very high resolution level, and if we know the exact phase states of the material, the structural phases, then we can control it, — explained Alexander Malikov.
Scientists will have even more opportunities with the launch of the Siberian Ring Photon Source (SKIF), at one of whose workstations a number of studies in this area are already planned.
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