The Main Defects and Ways to Improve the Quality of Layer-by-Layer Sintered Gas Turbine Parts

The paper investigates the possibility of improving the quality of engine parts in the process of layer-by-layer synthesis at the stage of prepress. It was found that in the processes of manufacturing parts using 3D printing, the mechanical properties of the final products are influenced by various factors, such as the quality of the powder for printing and the parameters of layer-by-layer synthesis. The most common defects in 3D printing are investigated in this work. It is shown that the quality of the product is significantly affected by the formation of internal stresses, which leads to warping of the product, and the incorrect design of the supports also leads to the need for additional machining. For a preliminary assessment of the influence of printing modes on the properties of products, the stress-strain state was modeled in the ANSYS environment for various modes and strategies of layer-by-layer synthesis of an engine part. Residual stresses and deformation of products were assessed depending on the printing strategy, the position of the part was determined corresponding to the minimum level of warpage of the part during the printing process. The approach proposed in the work allows at the stage of prepress to develop recommendations for choosing the position of the part and modes of layer-by-layer synthesis, depending on the purpose of the engine parts. But the limitation is the significant resource consumption of this process. The main defects arising in the details in the layer-by-layer synthesis process and ways to eliminate them are classified.