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


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



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.


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


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