Promising Constructive Solutions Try-Out with Additive Manufacturing in Space-Rocket Technology

Aeronautical and Space-Rocket Engineering


Аuthors

Alifanov O. M.1*, Lukomskii D. K.2**, Polovnikov D. E.1***

1. Moscow Aviation Institute (National Research University), 4, Volokolamskoe shosse, Moscow, А-80, GSP-3, 125993, Russia
2. Corporation Moscow Institute for Heat Technology, 10, Beryozovaya alleya St., Moscow, 127273, Russia

*e-mail: o.alifanov@yandex.ru
**e-mail: onion13@mail.ru
***e-mail: depolovn@gmail.com

Abstract

Ever-increasing requirements for modern and advanced space technology products create the need to apply advanced methods for their elaboration, which may consist in changing typical design solutions and application of new production methods.
The article considers prospective solutions in the context of such actively popularity gaining production method as additive technologies. The main advantage of additive technologies consists in the ability to manufacturing products of complex shapes, inaccessible or inexpedient for production by other methods, which allows applying optimization methods in full strength while the structure developing
The purpose of the article is prospective areas identifying and their application try-out. Within the framework of this article the authors consider a number of prospective design solutions in the context of the additive production technologies application. Thus, additive technologies are expedient to be applied for the labor intensity reduction while large-sized assembly units manufacturing. The authors proposed an additive-welding approach to the billets manufacturing of large-sized structural elements, which consists in integration of the structure constituent parts into a single case-shaped part with its further splitting into the segments, each of which may be manufactured by the 3D-printing equipment, with their further mergence by laser welding. As long as the billet being obtained is brought near geometry of the final product, it requires minimum machining. The accuracy of manufacturing may be controlled by both standard methods and measurements with the control-and-measuring machine or 3D-scanning, depending on its geometrical shape complexity, while the quality of printing and welding can be checked by either radiography or ultrasonic testing.
To reduce the product weight while additive technologies application, it is advisable to employ the structures with cellular filler. The multilayer sandwich panels of complex shape and variable cross-section, as well as the structures obtained as the result of the cellular optimization may serve as the example of such structures.
Within the framework of this article, technological try-out of a combined structure manufacturing was performed, and the possibility of producing a cellular structure with the specified parameters and required accuracy was confirmed.
The above-described approach offers prospects for application in real structures after conducting additional research with regard to the mechanical properties determining of the filler.

Keywords:

additive technologies, 3D-printing, additive production, structure optimization cellular structure, technological try-out, structure weight saving, production labor intensity reduction

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