The Russian State agency Rostec (Ростех) and the Chernyshev – United Engine Corporation (UEC) have begun the creation of a specialized center to research advanced additive manufacturing applications for defense and aerospace. The new Engineering Center for Additive Technologies (ICAT) has been named after named had been announced exactly a year ago and is now being built within the complex of the Chernyshev Moscow Machine-Building Enterprise, one of the leading companies of the Russian Defense Industrial Complex (specializing in jet engine production),
With the support of the Management Company (UEC) and the Rostec Group of Companies, the Chernyshev Enterprise is working on the implementation of high-tech production projects, such as the Center for Additive Technologies and various Smart Factory applications. The Moscow-based enterprise is also interested in the development and practical application of ideas and concepts related to Industry 4.0 within the National Technology Initiative.
The new additive center is part of the All-Russian Institute of Light Alloys (VILS), whose tasks include a full range of activities – from identifying needs for the use of additive technologies at Rostec enterprises to the implementation of new turnkey solutions. More than 30 enterprises within Rostec have already announced their readiness to discuss the conditions and prospects for joint work within the Engineering Center of Additive Technologies.
The Engineering Center of Additive Technologies has been built to work in the interests of Rostec enterprise, focusing on the collective use of additive technologies. Specialists of the center coordinate research work, processes of selection and adaptation of solutions for the use of additive technologies, as well as digitization and control of geometric parameters in production. The Russian center is in many ways similar to the UK’s MTC, Singapore’s NAMIC and other State-private collaborations that facilitate the advancement and adoption of AM within the manufacturing industry.
The cooperation of scientists and producers on the basis of a new center will allow in due course to ensure full import substitution in the production of materials for additive technologies.Alexander Nazarov, Deputy Director General of Rostec
“The introduction of additive 3D modeling and production technologies using 3D printing is one of the most dynamically developing areas of world metallurgy,” said Deputy Director General Rostec Alexander Nazarov. “The task of the Rostec State Corporation is to provide the Russian metallurgical industry with the opportunity to use these technologies to support national sovereignty in the field of aerospace, energy, shipbuilding.”
One of the key objectives for the cooperation of scientists and producers within the new center is to ensure the ability to produce materials for AM locally, without relying on imports. Preliminary talks on cooperation were also held with suppliers of equipment and supplies for additive production and digital measurements.
To ensure the import substitution of consumables in additive production, the possibility of creating a modular plant within the OJSC ( the All-Russian Institute of Light Alloys) for the production of powders of various alloys is being studied. This product is applicable both for new and for classical production methods, which will contribute to increasing the competitiveness of Russian granular metallurgy and at the same time reducing the cost of domestic metallurgical products.
OJSC is a strategic enterprise in the field of creating new technologies and producing metallurgical products from special alloys. The VILS Institute has a closed metallurgical production cycle integrated with the testing and research base. In the innovative portfolio of the Institute, there are 97 patents. Scientific personnel and production facilities are concentrated on a single site in Moscow. The largest shareholder of JSC “VILS” is the State Corporation Rostec.
One year and several million rubles later
The center is now undergoing final construction and it is expected to focus on additively manufactured parts in titanium, cobalt-chromium, stainless steel, Inconel and aluminum, as well as testing and certification of new products. The first pilot batch of parts is expected to be delivered sometime during 2019.
Project participants believe that the Center for Additive Technologies will be able to assume a leading position within the Russian manufacturing industry and become a center of excellence for introducing new technologies into production.
We use these technologies today: in one year we already produce about three tons of additively manufactured parts within UEC companies.Yury Shmotin, Deputy Director General and General Designer, UEC.
“Our task is to form a single production and design environment for introducing additive technologies, taking into account the best world practices. In the direction of additive technologies. These technologies make it possible to halve the number of parts in a number of gas turbine engine assemblies, and also provide the opportunity to apply a different thinking approach to form creation,” Deputy Director General and General Designer at UEC, Yury Shmotin, stated. “This allows to not only reduce the number of parts, but also reduce the overall cost of the engine. We use these technologies today: in one year we already produce about three tons of additively manufactured parts within UEC companies.”
As highlighted in the press report, the development of additive technologies is consolidated at all enterprises of the UEC. The holding plans to use them in the serial production of promising Russian gas turbine engines, which will be certified in 2025-2030.