Here are considered the main aspects of the nanotechnology application in the production of aircraft gas turbine engines. Here are presented possibilities of synthesis technology of the thermal barrier coating on cooled turbine blades of next generation GTE, technology of nanostructured multilayer coatings for metal cutting tools. Here is made actual the issue of industrial production of leucosapphire single crystals. In conclusion, here are presented competence-based personnel training educational programs for nanoindustry companies

Kozhina, Tatiana

English

GISAP (Global International Scientific Analytical Project): Scientific Journal

Technical Sciences, Construction and Architecture
6
Aeroengine construction is the in-dustry which includes the resultsof research and development of
scientists and engineers from many high-
tech areas, herewith almost all the technical
solutions are based on the essential basic
research in the sphere of engines, gas dyna-
mics, combustion and heat transfer, structural
integrity theories, and the theory of integral
and intelligent control and diagnostics. The
work for creation of innovative products in
the aeroengine construction sphere can not
be performed without the use of a high-
level computer multi-disciplinary simulation
and a physical modeling test and field testing
of components and engines as a whole
using of a unique simulating test benches.
The development of gas turbine engines
for aircrafts and for ground applications
marks tendency to increase the temperature
in the combustion chambers of gas turbines
from 1300 ° C to 1700 ° C, and the pro-
spective gas turbines to ultrahigh temperatures
of 2000 ° C, providing an increase of effici-
ency and performance factor of gas turbine
engines. The increase of operating tempe-
ratures of gas turbines makes it especially
urgent to introduce new high-performance
thermal barrier coatings for thermo-loaded
gas turbine components - flame tubes of
the combustion chamber and cooled blades
of the first stages of the turbine.
University scientists developed the synt-
hesis technology of thermal barrier coatings
on cooled turbine blades of a new generation
GTE, which includes the steps of applying
a heat-resistant metal layer Al2O3, with α -
a modified crystal lattice by ion-plasma
method and heat-resistant ceramic layer by
vapor deposition on the vacuum electron
beam unit. Directions of workflow optimi-
zation and an optimization criterion – ply
rating, the essence of which is to model the
synthesis of nanostructured coatings Al2O3,
allowing to eliminate the phase instability
and low adhesion of its components (Figure
1) are proposed.
Continuous improvement of aircraft
engine design, extensive use of hard materials
for critical parts with high accuracy of
working surfaces led to a large scale imple-
mentation of machine tools with CNC, ma-
chining centers, transfer lines and other ex-
pensive equipment that requires a consid-
erable intensification of the cutting parameters
that causes an increased tool consumption
as a result. One of the effective ways to
reduce a tool consumption while achieving
a high level of processing is the use of
metal tools with a wear-resistant coatings.
Wear-resistant coatings allow to get working
surface of a tool with a desired service
characteristics, usually without changing
УДК 620.3, 621.4
PROSPECTS OF NANOTECHNOOGIES IN AEROENGINE CON-
TRUCTION
Kogina T.D., 
Dr. of Engineering, Prof.
Rybinsk State Aviation 
Technical University of P.A.
Solovyev, Russia
Conference participant,
National championship in scien-
tific analytics
Here are considered the main aspects of the nanotechnology application in the production of
aircraft gas turbine engines. Here are presented possibilities of synthesis technology of the thermal
barrier coating on cooled turbine blades of next generation GTE, technology of nanostructured
multilayer coatings for metal cutting tools. Here is made actual the issue of industrial production
of leucosapphire single crystals. In conclusion, here are presented competence-based personnel
training educational programs for nanoindustry companies.
Keywords: nanotechnology, aeroengine manufacturing, nanoindustry, gas turbine engine,
turbine blade, leucosapphire single crystal, personnel, educational program.
Figure 1. Operational life of thermal barrier coatings of cooled turbine blades
at the temperature 1100 °С.
Technical Sciences, Construction and Architecture
the properties of the main tool. Therefore,
nowadays tool manufacturers, like Sandvik
Coromant, Iscar, Dormer, Walter, JSC "NIR",
Kirovograd carbide factory, etc., are being
developed in the following areas: improving
the geometry and the material of the cutting
end, the development of wear-resistant coat-
ing technologies.
Nanostructured multilayer coatings con-
sisting of several layers separated by thin
intermediate are becoming more common
nowadays. The coating technology allows
to give them the characteristics needed for
specific processing conditions, and to ensure
that the coating effectively complements
the physical and mechanical properties of
the substrate of the carbide. In a multi-layer
coating each wear layer performs its function,
improving the performance of the cutting
edge. By varying the composition and thick-
ness of the layers, you can create cutting
edge of hard alloys, designed for processing
a certain group of materials for specific op-
erations or for universal application for dif-
ferent workpiece materials and working op-
erations.
RGATU by P.A. Solovyov has conducted
researches to improve the performance of
carbide cutting tools with wear-resistant
coatings, used for GTE machining. The
mechanism of influence of a multi-layered
coating architecture on its structural pa-
rameters, mechanical properties, wear and
breakdown (Figure 2) is developed. It is es-
tablished that the effective resistance of a
delamination spread of a wear layer can be
raised or lowered by thermal stresses, that
are realized by a sudden temperature change
of the coating layer.
The study found that the use of a damp-
ing multilayer coating AlTiN-TiN-Ti (with
variable thickness of AlTiN), prepared by
high-speed magnetron sputtering, significantly
increases the efficiency of carbide end mills.
This allows to expand their use in machining,
where there are loads that often cause the
destruction of conventional coatings at the
very beginning of work, especially when
milling carbide workpieces with large cutting
thickness. The developed in the University
technology of optimization of the coating
process of wear resistant nanostructured
coatings of solid carbide end mills by the
boundary delamination complex includes
an extensive set of factors that determine
the resistance of the coating, including the
physical and mechanical properties of the
treated and tool material, cutting conditions,
the geometric parameters of the cutter, that
allows to predict the structure of the multilayer
coating on the stage of productions tooling
of end mills.
In the field of aviation instrument
making RGATU by P.A. Solovjov together
with JSC "RIMP" run an innovative project
for the technology development and industrial
production in an industrial scale of single-
crystal leucosapphire weighing up to 30 kg
for electronics, optoelectronics, optics, pre-
cision mechanics, instrument making and
laser technology.
Leucosapphires are used to create high-
brightness LEDs, for the development and
production of pastes for the metallization
of solar cells, which are one of the most
7
Figure 2. Mills with nanocomposite wear-resistant coatings and results of thickness monitoring of tool coatings using caliper
«Calotest»
Technical Sciences, Construction and Architecture
8
promising segments of the renewable energy
market. In the future - the development of
technologies for producing shaped crystals
of ruby refractory compounds, aluminum
yttrium garnet, etc. Work is underway to
transition to a more efficient technological
equipment for leucosapphire crystal growth
by Kyropoulos method, that allows to obtain
leucosapphire single-crystal boules weighing
up to 60 kg, used in the construction of
space ships and aircrafts.
It should be noted that it is of great im-
portance in the development of any field of
science and technology not only high-end
engineering technologies, but also educa-
tional.
Analysis of the situation with qualified
personnel for high-tech companies, as well
as the situation in the regional segment of
the labor market has shown that there is not
a quantitative deficit, when there are experts,
but their number is not sufficient, and the
qualitative and structural shortage. In fact,
the profession reproduction in many im-
portant areas has stopped, and the educational
system in institutions of vocational education
behind the changes in the field of practices.
The situation with staffing science intensive
plants hampered by the lack of effective
forms of interaction between the system of
training and professional sphere of con-
sumption. The labor market is stripped from
mechanisms for the influx of new staff and
young professionals in the industry.
Thus, nowadays there are no most
critical elements of infrastructure of staffing,
as well as the reproduction of human re-
sources for aeroengine industry, rocket,
ship, instrumentation and other high-tech
industries.
The task of forming an efficient infra-
structure of staffing of high-tech sectors of
industry can not be solved within an enter-
prise, it requires the participation and the
consolidation of the efforts of many parties:
public authorities, associations of producers,
institutions, corporate training centers, in-
formation centers and specialized agents of
the labor market. Therefore, it is taken to
consider the regional training systems and
attracting engineering and management staff
to the company as the basis of stuffing the
high-tech industry sectors.
In a shortage of highly skilled stuff on
the labor market aviation, aerospace industries
and other high-tech industries have to
develop and apply new technologies for
training and attracting staff.
On behalf of RSATU and with a support
of "Rosnano" technical training center for
specialists in the field of nanomaterials and
nanotechnology (UTC PS ERIP) was created
in 2010. The specialization of the centre
was based on the requests of employers. In
particular, the training of qualified personnel
for industries, using axial tools with nanos-
tructured coating - on behalf of JSC "New
instrumental solutions." Training according
to the program "Technologies of leucosap-
phire single crystal and other refractory
crystals growth for electronics and instru-
mentation" is held under contract with JSC
"Rybinsk instrument making plant." Training
and retraining of personnel in the sphere of
synthesis of termobarrier nanostructured
coatings of GTE hot parts – on behalf of
JSC "NPO Saturn" and JSC "Saturn-Gas
Turbines."
The educational programs of technical
training center are based on a modular ap-
proach, which provides the ability to create
optional specializations to enhance training
in a specific direction.
Education of the specialists, as well as
improving of their skill level is based on
the competency curriculum, which is the
main document. A feature of this curriculum
is to focus not on the training set of topics
and subjects taught in a certain volume, but
on the received practical knowledge and
skills that enable professionals to successfully
meet the challenges related to the develop-
ment and production of modern high tech
machines.
There is an opportunity to create spe-
cializations as part of specialties and areas
of training and retraining. Specializations
are part of the specialty in which they are
created, and expect to obtain deeper pro-
fessional knowledge in a particular specialty
profile. Number of hours (laboriousness)
for disciplines of the specialization should
be based on the discipline specificity.
One of the problems that require joint
decision by educational institutions and en-
terprises is to define the requirements for
the competence of engineers involved in
the production process, and the definition
of the competences required to perform
specific functions in the process, the imple-
mentation of their goals (objectives) and
the achievement of the planned results ac-
cording to the quality requirements. Joint
development of for company specialists al-
lows to design educational programs coor-
dinated with the strategy of the enterprise.
The competence models design for the
company specialists is performed under the
analysis of two interrelated systems: a com-
plete system of business objectives, defining
the area of final results that are achieved by
total implementation of all activities of the
company management; complete system
of enterprise processes and functions required
for the operational management under the
formed task system. The advantage of this
approach is that the process of defining the
required competencies of staff and their
subsequent development are related to the
processes of development, coordination and
implementation of organizational tasks. It
is provided the ability to change the re-
quirements for the staff competence in the
case of new enterprise development goals
and, therefore, the new features of employees
work in order to prevent the emergence of
inconsistencies in the manufacturing process
due to timely raise of the requirements to
the personnel competences.
The main assessment tools for in-
crease of the personnel competences
during the education and after it are
the following technologies: the use of
automated information system, meas-
uring the competencies using a test,
unification of the results into groups
of competencies, drawing of a radar
chart of student competences and over-
lay of it on the radar chart of required
competencies; self-appraisal of the
competencies change for the imple-
mentation of which each student is
provided with the available in the edu-
cational complex tasks for self-control
and control questions. It is also expected
to modify the automated information
system of competencies measurement
to enable on-line access for the students
involved in the training program.
In general, the developed two-level sys-
tem for training specialists provides the im-
plementation of an optimal training paths
for each student and allows to form the
necessary competencies for the program.
The proposed studying program can be
used to develop a competence-oriented pro-
gram of advanced training of personnel for
nanotechnology companies. Test scores after
the subjects studying, and the results of
graduation thesis are evident of the acquired
competences that will be used in the further
production activity of the specialists at the
nanoidustry and aeroengine production en-
terprises.


PROSPECTS OF NANOTECHNOOGIES IN AEROENGINE CONTRUCTION

https://journals.gisap.eu/index.php/Tech/article/download/53/47

PROSPECTS OF NANOTECHNOOGIES IN AEROENGINE CONTRUCTION

Abstract

Similar works

Full text

Available Versions

GISAP (Global International Scientific Analytical Project): Scientific Journal