The study of structural element of manned space complex manufactured by the wire electric arc technology of additive forming

Aeronautical and Space-Rocket Engineering


DOI: 10.34759/vst-2022-4-67-84

Аuthors

Ashimov I. N.*, Techkina D. S.**, Papazov V. M.

S. P. Korolev Rocket and Space Corporation «Energia», 4A Lenin Street, Korolev, Moscow area, 141070, Russia

*e-mail: ilyas.ashimov@rsce.ru
**e-mail: te4kina@yandex.ru

Abstract

The article considers application of the wire electric arc technology for additive forming in manufacturing a structural element of a manned spacecraft. The structural element represents a typical bracket for attaching equipment to the spacecraft body. For manufacturing by the additive growing technique, the source element was optimized for the printing technology capabilities and limitations. After optimization, a manufacturing process was formed, in which course the electric arc parameters were changed at various stages of printing. Manufacturing was being performed employing the AMg6 aluminum wire of a 1.2 mm diameter. As the result, the obtained structural element was tested for harmonic and static impacts. The purpose of the tests consisted in determining damping, strength and stiffness properties of the structure. The obtained test results were being compared with the computed finite element model. According to the analysis, under harmonic action, the frequency and form of oscillations of the first tone coincide with the computed ones (66 and 69 Hz, respectively). The damping coefficient in determining the amplitude-frequency characteristic and vibration impact was 2% and 2.5%, respectively, which allows accepting the obtained value as the damping coefficient of the material itself (in the first approximation). During static tests, the structural element collapsed under a load of 15300 N, the displacement herewith reached the value of 19.6 mm. The destruction occurred at the place of attachment to the power floor along the thinnest part of the bracket base. The fracture emergence is of a similar character with the maximum stresses occurrence in the finite element model, except of the primary fracture in the fusion zone of the material layers. Analysis of the material microstructure revealed the presence of gas pores from 20 to 500 microns. The chemical composition corresponds to the AMg6 alloy, though without manganese (Mn) on its surface. The results of the study revealed that the manufactured structural element withstood operational loads, and the printing technology was possible and efficient to be employed with certain assumptions for the studies of additive technologies under conditions of low gravity at the orbital space station.

Keywords:

additive technologies, structural element, electric arc technology, manned complexes, orbital space station

References

  1. Popovich A.A., Sufiyarov V.Sh., Razumov N.G. et al. Materialy 11 Mezhdunarodnogo simpoziuma «Poroshkovaya metallurgiya: inzheneriya poverkhnosti, novye poroshkovye kompozitsionnye materialy. Svarka» (10-12 April 2019; Minsk). Minsk, Izdatel’skii dom «Belorusskaya nauka», 2019, pp. 73-92.
  2. Raevskii E.V., Tsyganova A.L. Additivnye tekhnologii, 2016, no. 1, pp. 10-12.
  3. Baranov D.A., Lukin E.B., Zhukov V.V. et al. Additivnye tekhnologii, 2021, no. 3, pp. 4-7.
  4. Chumakov D.M. Trudy MAI, 2014, no. 78. URL: https://trudymai.ru/eng/published.php?ID=53682
  5. Panchenko O.V., Kurushkin D.V., Popovich A.A. Tekhnicheskii opponent, 2020, no. 1(6), pp. 16-22.
  6. Ashimov I.N. Materialy XXII Nauchno-tekhnicheskoi konferentsii uchenykh i spetsialistov, posvyashchennoi 60-letiyu poleta Yu.A. Gagarina, 75-letiyu raketno-kosmicheskoi otrasli i osnovaniya RKK «Energiya»
    (13-17 September 2021; Korolev, Moskovskaya oblast),     pp. 45-46.
  7. Weglowski M.St., Btacha S., Jachym R. et al. Electron beam additive manufacturing with wire. Electrotechnica and Electronica, 2018, vol. 53, no. 3-4, pp. 74-78.
  8. Eliseev A.A., Utyaganova V.R., Vorontsov A.V. et al. Izvestiya vuzov. Tsvetnaya metallurgiya, 2020, no. 4, pp. 65-73. DOI: 10.17073/0021-3438-2020-4-65-73
  9. Su C., Chen X., Gao C., Wang Y. Effect of heat input on microstructure and mechanical properties of Al-Mg alloys fabricated by WAAM. Applied Surface Science, 2019, vol. 486, pp. 431-440. DOI: 10.1016/j.apsusc.2019.04.255
  10. Oskolkov A.A., Matveev E.V., Bezukladnikov I.I. et al. Vestnik Permskogo natsional’nogo issledovatel’skogo politekhnicheskogo universiteta. Mashinostroenie, materialovedenie, 2018, vol. 20, no. 3, pp. 90-105. DOI: 10.15593/2224-9877/2018.3.11
  11. Trubashevskii D.S. 3D TODAY, 2019. URL: https: //3dtoday.ru/blogs/ddmlab/perekhod-k-provolochnym-tekhnologiyam-trend-ili-neobkhodimost
  12. Chen X., Su C., Wang Y., Siddiquee A.N. et al. Cold metal transfer (CMT) based wire and arc additive manufacture (WAAM) system. Journal of Surface Investigation: X-ray, Synchrotron and Neutron Techniques, 2018, vol. 12, no. 6, pp. 1278-1284. DOI: 10.1134/S102745101901004X
  13. ARC Mate 100iD — Robot dugovoi svarki. FANUC. URL: https://www.fanuc.eu/ru/ru/роботы/страница-фильтра-роботов/дуговая-сварка/arcmate-100id
  14. Balyakin A.V., Skuratov D.L., Khaimovich A.I., Oleinik M.A. Direct laser fusion application for powders from heat resistant allows in engine building. Aerospace MAI Journal, 2021, vol. 28, no. 3, pp. 202-217. DOI: 10.34759/vst-2021-3-202-217
  15. Klimov V.G. Comparison of turbine blade wing of heat-resisting alloy geometry restoring techniques. Aerospace MAI Journal, 2016, vol. 23, no. 1, pp. 86-97.
  16. Kisarev A.V., Kobernik N.V. Study on formation of aluminum alloy thin wall produced with WAAM method under various thermal conditions. 3rdInternational Biannual Conference "Electron Beam Welding and Related Technologies (12–15 November 2019, Moscow, Russian Federation). DOI: 10.1088/1757-899X/759/1/012014
  17. Veiga F., Sua2rez A., Aldalur E., Bhujangrao T. Effect of the metal transfer mode on the symmetry of bead geometry in WAAM aluminum. Symmetry, 2021, vol. 13, no. 7. DOI: 10.3390/sym13071245
  18. Matviichuk V.A., Nesterenkov V.M., Rusynik M.O. Application of additive electron beam technologies for manufacture of metal products. Electrotechnica and Electronica, 2018, vol. 53, no 3-4, pp. 69-73.
  19. Shtepmfer F. Method and arrangement for building metallic objects by solid freedom fabrication. Patent EA024135B1, 31.08.2016.
  20. Herzog D., Seyda V., Wycisk E., Emmelmann C. Additive manufacturing of metals. Acta Materialia, 2016, vol. 117, pp. 371–392. DOI: 10.1016/j.actamat.2016.07.019

mai.ru — informational site of MAI

Copyright © 1994-2024 by MAI