Additive manufacturing of a complex-integrated structure of a micro jet engine by powder bed fusion

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Abstract

BACKGROUND: Development of micro jet engine is associated with scaling problems, leading to a sharp decrease in the Reynolds number and an increase in the influence of the roughness of the internal surfaces of the engine elements on hydraulic losses and overall efficiency. The selection of technological modes of additive manufacturing by powder bed fusion of a complex-integrated structure of a micro jet engine makes it possible to analyze the nature of surface roughness changes and to determine the optimal manufacturing modes.

AIM: Study of the effect of technological modes of powder bed fusion on the roughness of the resulting surfaces and development of a method for selecting printing parameters to minimize the hydraulic resistance in the flow part of a complex-integrated structure of a micro jet engine.

METHODS: Experiments on the production of samples made of the heat-resistant nickel alloy 08KhN53BMTYu have been carried out. The ranges of volumetric energy density and layer thickness were studied. The roughness was measured, a theoretical analysis of hydraulic losses in a combustion chamber was conducted.

RESULTS: The dependences of the surface roughness on the volumetric energy density and the layer thickness are found, and the lowest roughness values are determined. Based on the data obtained, diagrams linking the printing mode with critical Reynolds numbers, at which roughness begins to affect the flow, and the calculated coefficient of friction resistance for channels of various equivalent diameters, are built.

CONCLUSION: A methodological approach to the selection of technological modes of powder bed fusion for additive manufacturing of a complex-integrated structure of a micro jet engine has been developed. The obtained dependences make it possible to evaluate the effect of printing parameters on the roughness, which is necessary to optimize the process of additive manufacturing of complex-profile micro jet engine elements.

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About the authors

Anton V. Pobelyanskiy

Baltic State Technical University “VOENMEKH” named after D.F. Ustinov

Email: pobelyanskiy@inbox.ru
ORCID iD: 0009-0003-0492-5879
SPIN-code: 4369-7020

Head of Additive Technologies and Volumetric Scanning Center

Russian Federation, Saint-Petersburg

Andrey A. Shirokikh

Peter the Great St. Petersburg Polytechnic University

Author for correspondence.
Email: andreyka-29@mail.ru
ORCID iD: 0009-0006-7621-0778
SPIN-code: 8501-4351

Engineer of the Higher School of Power Engineering

Russian Federation, Saint Petersburg

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Supplementary files

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2. Fig. 1. Complex-integrated structures of a combustion chamber of a micro jet engine.

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3. Fig. 2. Ra = f (E) dependence.

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4. Fig. 3. Dependence of the maximal Reynolds number on the volumetric energy density, the beginning of the influence of roughness at manufacturing of a complex-integrated structure of a micro jet engine made of 08KhN53BUMTYu material.

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5. Fig. 4. The dependence of the maximal Re on the volumetric energy density E, the beginning of the full extent influence of roughness at manufacturing of a complex integrated structure of a micro jet engine made of 08KhN53BUMTYu material.

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6. Fig. 5. Dependence of the coefficient of friction resistance on the volumetric energy density E for the roughness impact mode in a complex integrated structure of a micro jet engine made of 08KhN53BUMTYu material.

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7. Fig. 6. The resistance of the rough channels of a complex integrated structure of a micro jet engine made of 08KhN53BUMTYu material.

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