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High-tech production facilities
UEC-Saturn’s production facilities enabling manufacture of gas-turbine components of any complexity, dimensions and mechanical characteristics. The metal-processing equipment stock amounts to over 12000 units, including about 2000 units of metallurgical equipment. Science-intensive technologies for manufacturing parts of composites, structural ceramics, and bimetals are widely used in pilot and series production. [imgx class="block" src="img/editifr/2015/23_0_s2.jpg"]
Design-Manufacture integrated information system
• simultaneous product design, development of processes and manufacture of tooling on the basis of 3D models • integrated electronic database of manufacturing processes and documentation • QuickCast build style pattern (stereolythography) of the most complex parts • industrial network of data transmission to CNC machines • automated production planning system • automated production cost accounting system [imgx class="block" src="img/editifr/2015/23_0_s3.jpg"]
Casting techniques
• casting patterns manufacture by means of stereolythography technique • single crystal blade casting technique • refractory coating • high-temperature vacuum heat treatment of parts with high-speed cooling • isostatic pressing of turbine blades and vanes, recovery of blades and vanes properties and structure while in repair • manufacture of ceramic cores using the solid-phase sintering method [imgx class="block" src="img/editifr/2015/23_0_s4.jpg"]
Welding, brazing, gas-thermal coating application techniques
• electron-beam welding • gas-shielded welding • argon-shielded welding of complex-shaped parts in the chamber • high-temperature vacuum brazing • gas-thermal deposition of sealing and wear-resistance coatings [imgx class="block" src="img/editifr/2015/23_0_s5.jpg"]
Machining
• turning of external and internal complex-shaped compressor and turbine shafts surfaces • five-axis machining technique of blisks • high-speed machining of large- and medium-size compressor blades (from modeling the machining process within the Vericut system to on-machine manufacture by circle milling) • finish six-axis programmable dressing with an endless abrasive belt • finish vibro-abrasive machining of complex-shaped parts [imgx class="block" src="img/editifr/2015/23_0_s6.jpg"]
Heat treatment techniques
• heat treatment of parts at a heating temperature up to 1350°С and cooling rate up to 300°С/min • heat treatment and welding-up of parts in vacuum and shielded gas atmosphere • vacuum-flame deposition • ion nitriding [imgx class="block" src="img/editifr/2015/23_0_s7.jpg"]
Electrical discharge machining and electrochemical processing
• processing of granular disks and perforated holes in turbine blades by electrical discharge machining • broaching of slots and pockets in parts from hard-to-process high-temperature alloys • wire cutting of various configuration parts and components • small compressor blades manufacture by electrochemical processing [imgx class="block" src="img/editifr/2015/23_0_s8.jpg"]
Protective coating application techniques
• heat-resistant coatings on turbine part surfaces by ion-plasmous method • protective coatings on inner and outer surfaces of blades and vanes by gas-circulation method (chrome aluminizing, aluminizing) • laser powder cladding of turbine blades contact surface [imgx class="block" src="img/editifr/2015/23_0_s9.jpg"]
Laboratory facilities
• X-ray inspection of turbine blade and vane castings • FPI inspection of turbine blade and vane castings, with S2, S3, S4 sensitivity • mechanical tests of turbine blade and vane castings (elongation at room/increased temperature, creep-rupture test, etc.) • chemical analysis of turbine blade and vane castings by opticospectral method, wet analysis, gas analysis of impurities, ISP gas analysis |
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