Translation. Region: Russian Federation –
Source: Peter the Great St. Petersburg Polytechnic University –
An important disclaimer is at the bottom of this article.
As part of a joint R&D project, Peter the Great St. Petersburg Polytechnic University and Power Machines developed a technology and produced the largest printed part in Russia using electric arc deposition.
The steam turbine seal blank weighs over 750 kg, setting an absolute national record. The work was conducted at the Lightweight Materials and Structures Laboratory of the Institute of Mechanical Engineering, Materials, and Transport at SPbPU.
The main goal of the R&D project is to create a robotic arc-growth system and develop a technology for manufacturing blanks for the turbine production of Power Machines. The primary materials for this type of product are high-strength, low-alloy, heat-resistant steels.
The technology behind electric arc deposition from metal wire is based on the layer-by-layer transfer of molten metal. The metal is melted using the energy of an electric arc. All movements are performed by an industrial robot, which follows a specially developed program. Specialists program the movements, taking into account the influence of wire feed speed, arc power, wire metal composition, and other factors on the characteristics of the future part. To print the part, the print layer width was increased to 201 millimeters. Such a massive layer inevitably leads to significant deformations of the product relative to the 3D model. Engineers developed a special printing approach to compensate for this.
During the development of the electric arc growth technology for such workpieces, a huge amount of data was collected through a series of experiments. These experiments included the development of metal transfer modes during growth, material behavior studies, the development of growth control programs, and many other parameters. This project opens up the prospect of producing even larger parts, effectively pushing the limits of additive manufacturing capabilities for industry. Crucially, in addition to developing the growth technology itself, the Polytechnic University is manufacturing electric arc growth equipment for JSC Power Machines as part of the joint project. "Domestic science ensures technological leadership for the domestic industry," noted Oleg Panchenko, Head of the Lightweight Materials and Structures Laboratory.
The implementation of innovative manufacturing methods is a key focus of Power Machines' capacity development program. Additive manufacturing helps us implement new engineering solutions, ensure the efficiency and reliability of our generating equipment for the Russian energy sector, and reduce manufacturing lead times and costs. After launching the robotic complex and fine-tuning the technology, we are potentially considering expanding this manufacturing method to critical steam turbine cylinder blanks, said Alexander Ivanovsky, First Deputy General Director and Chief Designer of Power Machines.
It's worth noting that St. Petersburg Polytechnic University is a recognized leader in additive manufacturing in Russia. The Laboratory of Lightweight Materials and Structures has been continuously modernizing and developing electric arc deposition technology since 2015. Engineers have extensive experience in the electric arc deposition of a wide range of materials, including high-strength steels, austenitic and austenitic-martensitic stainless steels, ultra-high-strength steels, and aluminum-, copper-, nickel-, titanium-, and magnesium-based alloys. Electric arc deposition is a process related to welding and surfacing, placing high demands on specialists. Knowledge in materials science, industrial robotics, and programming are essential. All this allows us not only to fulfill orders for industrial partners but also to develop the most advanced tools and manufacturing technologies.
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