Translation. Region: Russian Federal
Source: Peter the Great St. Petersburg Polytechnic University –
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Employees IMMIT SPbPU Conducted work under a contract for research, development, and engineering work on the topic: "Development of a design and manufacturing technology using additive manufacturing for critical hot-path components of the T32 gas turbine unit (MS5002E)." The project manager is Anatoly Popovich, Director of the Institute of Metallurgical Engineering and Metallurgical Engineering.
During their work, specialists from the LiAT Research Laboratory examined the first- and second-stage high-pressure turbine nozzle vanes, developed repair documentation, and conducted pilot repairs using laser cladding. They analyzed the operating conditions of the first- and second-stage nozzle assemblies and the condition of the nozzle vane material after operation, classified defects by type, size, and location, and developed a method for identifying defective blades.
At the end of 2023, work began on a project with Gazprom to repair first- and second-stage high-pressure turbine nozzle blades. After lengthy negotiations and detailed discussions, active work began on analyzing the received parts and developing a laser cladding repair technology for the SL1 and SL2 high-pressure turbine blades of the MS5002E gas turbine engine (GPA Ladoga 32). "Thanks to the use of laser cladding, we were able to increase the service life of the parts," shared Mikhail Kuznetsov, head of the LiAT Research Laboratory.
The specialists also conducted experimental studies of the properties of compact samples and developed a technological process for repairing parts, including heat treatment, mechanical processing, laser cladding, and incoming and outgoing inspection.
Together with colleagues from the Institute of Power Engineering, we conducted computational studies, including strength, gas-dynamic, hydraulic, and thermal methods. We also conducted a validation analysis of the repaired blades.
As part of another phase of R&D with Gazprom on import substitution of critical gas turbine components, Polytechnic University researchers developed a method for manufacturing T32 GTU fuel injectors using additive manufacturing. The injector is a key component of the combustion chamber, ensuring optimal combustion parameters. Researchers at the institute conducted research into the selection of a domestic heat-resistant alloy and developed selective laser melting modes. The developed method involves 3D printing individual injector components, post-processing, and laser welding. This significantly reduced manufacturing time and material consumption compared to traditional methods.
Laboratory tests of the test specimens included determining the material's mechanical properties at various temperatures, as well as long-term strength testing. The finished nozzles underwent pneumatic testing to verify flow characteristics and effective orifice area, confirming compliance with all technical specifications. Plans are currently underway to manufacture several sets of nozzles using the developed technology for hot testing within a gas turbine unit.
The development of a fuel injector manufacturing method using selective laser melting is an important step in the development of domestic power engineering. "We have succeeded in developing an effective solution based on domestic materials and equipment, ensuring technological independence of production," noted Igor Polozov, leading researcher at the Structural and Functional Materials Research Center.
Organizing knowledge-intensive small-scale production is a worthy pursuit for a research university. Our scientists, in collaboration with representatives of high-tech companies from various industries, are solving complex problems and developing the domestic industry. The successful and early completion of the R&D project with Gazprom speaks to the high professionalism of our employees and their desire to conquer new and challenging horizons, commented Anatoly Popovich.
Please note: This information is raw content obtained directly from the source. It represents an accurate account of the source's assertions and does not necessarily reflect the position of MIL-OSI or its clients.
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