The heat-loaded part of the combustion chamber of a liquid rocket engine are Considered. The proposed coating has several layers: an internal metal coating that contacts the part or substrate, and an external coating made of a mixture of ceramic granules and metal powder. At the same time, to obtain the initial surface for coating with the required surface layer roughness, it is proposed to use the method of sand blasting. The article analyzes possible mechanisms of material formation for "base-coating" transition zones, as well as the influence of their chemical composition on the adhesive strength of layers.. The choice of brand and combination of materials used for coating is justified. Technological modes that have been tested in production conditions when applying heat-resistant coatings to parts of modern rocket engines are proposed. The influence of technological parameters of the initial surface preparation process and the geometry of the resulting micro-relief of the substrate on the adhesion characteristics of a multilayer coating made of heat-protective materials operating in the high-temperature zone of the combustion chamber of liquid rocket engines is revealed.
Рассмотрена технология изготовления дополнительных элементов систем охлаждения ракетных двигателей в форме местных углублений, расположенных на имеющихся фрезерованных каналах на наружных поверхностях камер сгорания и реактивного сопла. Такая проблема требует решения в перспективных изделиях с повышенной теплонапряженностью зоны горения топлива. Проведен анализ конструкции и возможностей обработки дополнительных элементов охлаждения в донной части и на боковых поверхностях узких каналов с ограниченным доступом инструмента в зону удаления припуска. Изучены новые конструкции инструмента для комбинированной обработки с использованием шаблонов различной конструкции и обоснована возможность их использования для изготовления углублений в каналах. Предложены новые способы комбинированной локальной обработки углублений с несимметричной геометрией сечения, форма которых обоснована в процессе отработки технологичности конструкции создаваемых двигателей, что ранее считалось неосуществимым или чрезмерно трудоемким. Исследована возможность многоместной обработки локальных углублений для дополнительного охлаждения в каналах на участках с переменным профилем камер сгорания современных и перспективных изделий по многослойным шаблонам. Здесь разработанные комбинированные технологии дают наибольший эффект и способствуют повышению ресурса двигателей новых поколений до уровня, обеспечивающего многократное увеличение количества безотказных пусков космических систем, что значительно снижает затраты на изготовление ракетных двигателей новых поколений The article considers the technology of manufacturing additional elements of rocket engine cooling systems in the form of local recesses located on the existing milled channels on the outer surfaces of the combustion chambers and the jet nozzle. This problem requires solutions in promising products with high heat stress of the fuel combustion zone. We analyzed the design and processing capabilities of additional cooling elements in the bottom part and on the side surfaces of narrow channels with limited tool access to the allowance removal zone. We studied new tool designs for combined processing using templates of various designs and justified the possibility of their use for making recesses in channels. We propose new methods of combined local processing of recesses with an asymmetric cross-section geometry, the shape of which is justified in the process of testing the manufacturability of the design of the created engines, which was previously considered impossible or excessively labor-intensive. We investigated the possibility of multi-site processing of local recesses for additional cooling in channels in areas with a variable profile of the combustion chambers of modern and promising products using multilayer templates. Here, the developed combined technologies give the greatest effect and contribute to increasing the resource of new-generation engines to a level that provides a multiple increase in the number of trouble-free launches of space systems. This significantly reduces the cost of manufacturing new-generation rocket engines
Variants of manufacturing deep channels of different cross-sections in typical details of modern equipment are considered. Most of the methods were created with the participation of the authors of the article and are protected by Russian patents. The results of the research are implemented in production at enterprises of various branches of mechanical engineering. Information is given about the original methods of piercing deep holes with a depth-to-diameter ratio of more than 25:1 by using combined processes with the imposition of high-frequency vibrations and the possibility of obtaining holes of variable cross-section in pressed ceramic and metal workpieces. The production of mating surfaces from small cross-section channels and narrow grooves is considered,which allowed us to offer an original technological process for the erosive chemical production of precision parts. This technology has been used in the manufacture of parts whose traditional processing methods are poorly understood or not feasible.In particular, a new application of combined firmware for obtaining deep holes of small cross-section in metal workpieces obtained by pressing is shown.Typical parts containing deep channels are given, the combined processing of which is the most technologically advanced and allows for a high economic effect.
The paper considers new methods and tools for combined electroabrasive finishing of metal parts, and shows the advantages of such a tool over traditional methods of finishing shaping the surfaces of labor-intensive products made of difficult-to-process alloys. The possibilities of layer-by-layer application of materials using additive technology to reduce labor intensity and cost for combined processing of tools with layers of abrasive on the periphery of a metal body obtained from a low-melting alloy by the additive method are considered. The possibility of accelerated production of tools using this technology, which does not require significant costs for editing and sharpening for specific parts, is shown, which reduces the production time of technological equipment when launching new generations of products, primarily in the aerospace industry of mechanical engineering. The new method and design of the tool are protected by a Russian patent. Experimental operation of wheels made using additive technologies has shown that the use of such a tool in single and small-scale flexible structure production significantly reduces the complexity of manufacturing parts for finishing operations.
The analysis of results of technological impact research upon operation characteristics of science intensive products and the ways to increase parts life of a hot area in aircraft and rocket jet engines is shown. It is shown that the basic factor of promising products for life increase consists in thermal-insulation increase and cooling jet nozzles and combustion chambers. For this the investigations are carried out for new heat-resistant material and protective coating development.
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