Surface engineering combines methods for directional changes of physical and chemical properties of the material surface layers by deformation, modification, deposition of films, coatings, protective layers using various combined methods:
ion thermochemical treatment
laser treatment
nitrocarburizing
induction heating
magnetic-pulse treatment and others
ELECTRON-BEAM EQUIPMENT AND TECHNOLOGIES
ELECTRON BEAM PROCESSING EQUIPMENT
TECHNICAL CHARACTERISTICS
dimensions of the working chamber, mm (ø1350×2500)
beam power, kW (15)
accelerating voltage, kV (60)
residual pressure, Pa (10-2)
the pump-down time (required to achieve a working vacuum in the chamber ), min (no more than 20 minutes)
APPLICATION
welding and soldering of parts made from homogeneous and dissimilar materials, additive technologies for manufacturing products, surface hardening of steel products, combined and integrated processes of hardening, purification of metals
ADVANTAGES
a capability of local processing and three-dimensional machining of materials
automation of technological processes
products processing made from almost all metals and alloys (based on Fe, Cu, Al, Ni, Co, etc.), including high-purity (Nb, etc.) and highly active (Ti, Zr, etc.)
processing of products with a diameter up to 900 mm and a length up to 2000 mm
ELECTRON-BEAM WELDING TECHNOLOGIES
Obtaining permanent joints by melting a material with a concentrated electron stream. The kinetic energy of electrons focused in a beam of 0.1-1 mm in diameter is released during their deceleration
TECHNICAL CHARACTERISTICS:
energy density, W/cm2 (104–106)
welding speed, mm/s (1–25)
weld depth, mm (0,1–100)
weld depth to width ratio (1:2–50:1)
weld joint strength factor (0.9–1.0 of the strength of the base metal)
APPLICATION
welding of various components of a speed-change gearbox, shafts, gears, gear blocks, gear wheels, axles, reduction gear casing, clutch, truck double-reduction drive axle, steering columns, turbine rotors and other parts of large machine building enterprises
ADVANTAGES
capability to weld products made from Fe, At, Cu, Ti, Nb-based alloys (including dissimilar metals), heat-treated materials
insignificant thermal deformation of products
capability to weld thin and thick-walled parts
reduction in the number of parts in an assembly, as well as the material consumption decrease down to 50 %
increase in labour productivity up to 800 %
decreased assembly time by 40–80 %
increase in welding speed by more than 100 %
increase in efficiency of protection up to 35 times
energy per unit length of the weld is 5–10 times less as compared to arc welding
ELECTRON BEAM SOLDERING OF TOOLS EQUIPPED WITH SUPERHARD-MATERIAL ELEMENTS (CUBIC BORON NITRIDE AND POLYCRYSTALLINE DIAMOND)
Obtaining dissimilar material joints (ceramics – metal, superhard materials – substrate) with the use of adhesively-active alloys based on Cu and Ag
TECHNICAL CHARACTERISTICS
time of soldering, min (1–2)
tower consumption per piece, kJ (10–20)
SHM – substrate joint strength
tensile strength – up to 120 MPa
shear strength – up to 300 MPa
APPLICATION
engineering industry, toolmaking industry
ADVANTAGES
capability of processing with a blade tool with a cutting speed of 10–50 m/s of materials with a hardness up to 60–75 HRC; non-ferrous alloys; ceramics (silicified graphite, silicon carbide, etc.); metal matrix composite materials (MMC); carbon fiber reinforced plastics (CFRP)
superfinishing treatment of titanium alloys under coolant supply
high-precision processing
surface roughness is 0.63–0.05 μm
durability of tools (in comparison with carbide tools) increases by 25 times or more
SUPERCONDUCTING NIOBIUM RESONATORS
1.3 GHz resonators made from high-purity niobium. The production of resonators with the use of EBW provides preservation of the initial purity of the metal
TECHNICAL CHARACTERISTICS
temperature transition of the welded joint metal into a superconducting state, K (8,6)
critical magnetic field, T (up to 0.4)
transition width, T (of 0.2–0.25)
Q value at cryogenic tests (2.5 ∙ 109)
APPLICATION
components for creating accelerating equipment of the mega-science class
ADVANTAGES
an opportunity to participate in international projects on the development of particle accelerators
ADDITIVE PRODUCTION TECHNOLOGY OF METAL BLANKS BY LAYERED ELECTRON BEAM SURFACING
Layered electron-beam surfacing of wire along the trajectory, providing three-dimensional metal blank obtainment of preset geometric shape
APPLICATION
aerospace, energy, auto-building industries, medical implants production, appropriate in small batch or single production, high metal cost
ADVANTAGES
compared to casting and stamping
high coefficient of the material use (up to 95%)
simplicity of changing the design of the blank during its development
lack of costs for shape-generating rigging for every kind of product
a capability of blanks production of complex geometric shape
a capability of control the chemical composition of each layer blank
compared to powder additive technology
vastly lower costs of expendable materials (wire compared to spheroidized powder)
a capability of product bulky blank (up to 1m3)
high speed of blank manufacturing
wide metal and alloy selection in wire form
ELECTRON-BEAM SURFACE HARDENING
Modification of surface properties of parts made from structural and tool steels, titanium, aluminum and copper alloys by the following methods
electron-beam (EB) hardening from solid or liquid state
deposition of hardening coatings by surfacing
combined or integrated methods (EB processing by conventional methods of previously applied layers or coatings with thicknesses from tens to hundreds of micrometers)
APPLICATION
engineering industry, toolmaking industry
ADVANTAGES
local hardening
after electron-beam hardening an increased durability is observed (by 1,2–2 times) in comparison with products quenched in a furnace
after implementation of combined or integrated methods a 3–5 times wear resistance increase is observed
ELECTRON-BEAM FUSING WITH REFINING OF THE SURFACE BILLETS
Refining of metals and alloys from impurities and non-metallic inclusions, removal of surface defects, obtaining multicomponent alloys and coatings, targets-cathodes (Cr, Ti, Zr, Ti с Cr, Al, Zr) for arc and magnetron sputtering systems
ADVANTAGES
non-metallic inclusion reduction in steels by 1,5–7 times
increase of heat-resisting steel hardness (fusing and electron-beam hardening) – for НRC 2–3 in comparison with a hardness after a three-dimensional hardening
increase of thermal conductivity of refined steels in the range of 20–500°С – up to 50%
reduction of the impurity content in chrome of ВХ-2К grade – down to 70 times
increase of wear-resistance of metal-cutting tool with multicomponent coatings Ti,Al) N, (Ti,Zr)N and (Zr,Al)N in comparison with
with a tool without coatings by 1,6–2,5times
with a tool with TiN layers by 1,5–1,6 times
APPLICATION
targets-cathodes for arc and magnetron sputtering systems
CLOSE
ION THERMOCHEMICAL TREATMENT
ION THERMOCHEMICAL TREATMENT TECHNOLOGIES (NITRIDING OF STEELS, CAST IRONS, TITANIUM ALLOYS, CARBURIZING AND NITROCARBURIZING OF STEELS)
The surface diffusion alloying of parts, cutting and stamping tools, casting tooling, etc. with nitrogen and carbon in an abnormal glow discharge at a pressure of 80–350 Pa (nitriding) and 300–1000 Pa (carburization, nitrocarburization)
TECHNICAL CHARACTERISTICS
After nitriding of the steels
the microhardness of the surface HV0,1 (450-1200)
the layer depth, mm (0.1–0.5)
After nitriding of titanium alloys
the microhardness of the surface HV0,1 (750–1100)
the layer depth, mm (up to 0.1)
After carburization of the steels
the hardness of the surface (after quenching) HRC (58–63)
the layer depth, mm (up to 3.5–4)
APPLICATION
machine-building, automobile, tractor, aircraft, shipbuilding and ship repair enterprises, plants for the production of agricultural machinery, pump and compressor equipment, electric power installations, etc.
ADVANTAGES
in comparison with volumetric quenching, ion thermochemical treatment provides an increase in durability, fatigue endurance, antiwelding properties, heat resistance, corrosion resistance
compared to gas nitriding, thermochemical treatment provides processing time reduction by 2–5 times, diminishing consumption of working gases by 20–50 times, reduction of electricity consumption by 1.5–3 times, simplicity of shielding non-hardenable surfaces, prevention of an increased brittleness of the layer, full compliance with all requirements for environment protection
INDUSTRIAL EQUIPMENT FOR ION THERMOCHEMICAL TREATMENT
The ability to control the chemical activity of an abnormal glow discharge, depending on the type of material being treated, area of case hardening batch, and an operating temperature Pressure in the chamber and the consumption of each of the components of the gas mixture are controlled independently. The equipment is fully automated. The technologies are finishing, energy and resource-saving, environmentally safe
TECHNICAL CHARACTERISTICS
working space dimensions of door, bell or shaft type chambers
diameter, mm (400–2500)
height, mm (400–3200)
batch mass, kg (up to 3000)
discharge power, kVA (25–100)
working pressure is 80–350 Pa (nitriding) and 300-1000 Pa (carburizing, nitrocarburizing)
APPLICATION
all areas of mechanical engineering
ADVANTAGES
ensures reliability of the technology — the reproducibility of the processing results, regardless of the loading efficiency of the chamber
the ability to handle steels of different types: structural, tool, high-speed, stainless, cast iron of any type as well as titanium alloys
CLOSE
LASER TREATMENT OF MATERIALS
LASER HARDENING OF WEAR PARTS (HARDENING, ALLOYING)
Local hardening of working surfaces and edges of parts. The technology is based on the use of high heating rate of the surface layer to temperatures exceeding the temperature of phase transformations or alloy melting, and subsequent high-speed cooling by means of the main heat sink to the metal mass create a wide range of alloyed surface layers depending on the specific operating conditions
TECHNICAL CHARACTERISTICS
thickness of hardened layers, μm (100–1000)
microhardness of alloying zones, MPa (10000-15000)
microhardness of hardening particles, MPa (25000-28000)
APPLICATION
mechanical engineering, auto and tractor construction, machine-tool building, press and stamp production and etc.
ADVANTAGES
non-contacted local impact
minimum heat affected zone
high heating and cooling rates
level decline of residual voltage
no warping, increase of structure dispersion and etc.
LASER MODIFICATION TECHNOLOGY OF WEAR PARTS OF WORKING AGRICULTURAL MACHINERY PARTS
The technology of laser modification has been developed to obtain hardening layers with high hardness values on products with thin wedge-shaped parts that allows to combine high cutting, wear-resistant and strength properties of parts with their impact strength
TECHNICAL CHARACTERISTICS
depth of hardening zone, mm (0,2-0,4)
hardness of modified layers, HR (up to 65-70)
APPLICATION
knives for bark and beet harvesters, corn headers, rotary mowers and etc.
ADVANTAGES
high localness of hardening
minimum zones of thermal effect
working resource of the manufactured mower knives, knives pruning tops of beet harvesters by 2,5-3 times higher than domestic serial
LASER WELDING AND RECOVERY OF WORKING SURFACES OF MACHINING PARTS AND MECHANISMS
Local recovery and hardening of working surfaces of machining parts and mechanisms
TECHNICAL CHARACTERISTICS
hard facing materials on iron, nickel, cobalt and other substrates
thickness of hard facing layers, mm (up to 1,5)
APPLICATION
mechanical engineering, aircraft engineering, power and turbine equipment, press and stamp production, maintenance and others
ADVANTAGES
minimal heat-affected zone
residual strain reduction
minimal mixing of hard facing material with a substrate material and others
recovery of local wear cavity with simultaneous increase of mechanical properties of the surface
LASER WELDING OF DIAMOND CUTTING SEGMENT CIRCLES
Production of assembly units and tools with high quality of welded joints. Welding is performed on a special die tooling which enable to weld widely-used diameters of 200 to 400 mm including GOST 16115-88 requirements
TECHNICAL CHARACTERISTICS
thickness of welded steel plates is up to 4 mm
APPLICATION
mechanical engineering, repair
ADVANTAGES
strength of joints close to the strength of the base material
minimal distortion of welded components and structures
capability of reliable connection of difficult-to-weld materials by conventional methods
easy protection process of the welding area from harmful effects of the ambient air on metals
CLOSE
MAGNETIC PULSE TECHNOLOGIES
WELDING OF DISSIMILAR METAL MATERIALS BY PULSED MAGNETIC FIELD
Magnetic-pulse welding is welding of metal details through impact. Acceleration and throwing of welded parts is provided by a pulsed electromagnetic field. It is possible to weld almost any metal in a short period of time, calculated in microseconds during which only setting processes take place but diffusion processes do not have time to develop
APPLICATION
relevant to enterprises of machine, instrument, aircraft industries, at electro-technical industry for obtaining parts from metal of various structural fulfilment (rod-tube, rod-sheet, sheet-sheet, compound of metalware with body parts and ect.)
ADVANTAGES
capability to smoothly manage processes
high stability of welded joint properties due to precise dosage of the discharge energy
welding in protective atmosphere and vacuum is possible
MAGNETIC-PULSE PROCESSING OF MATERIALS (FORMATION)
The essence of the formation process through magnetic-pulse material treatment lies in the use of powerful pulse magnetic field. This effect allows to treat metallic and non-metallic materials without using traditional stamping equipment
ADVANTAGES
Sheet-metal forming
combining of separating, forming and assembling operations
absence of one operating part of a die-force plunger and matrix, the functions of which are fulfilled by a magnetic field or an elastic medium
increase of deformation degree and uniformity by 30 %
reduction of bur sizes and a springing degree
reduction of costs for die tooling by 5–20 times
capability of treatment without tool-billet contacting, while maintaining the initial quality of the surface
capability of treatment through the walls of a heating device, a vacuum chamber and a protecting cover
Assembly
increase of strength and reliability of joints due to post-deformation hardening, low springing and thermal shrink fitting;
combination of assembling of parts and separating, forming and grooving operations;
1.5–2 times reduction of joint electrical resistance and increase of strength, leak-tightness and heat resistance of cable lug assemblies and casing of coupling boxes with wires
high sterility of assembling due to the contact absence between the forming tool and assembly parts and a capability of assembling and hermetic sealing of vessels through the walls of chambers with a specific medium or vacuum
Powder materials formation
a high degree of material compaction due to pulse pressing
changing penetrability in a certain manner in filtering elements in a direction of filtration
formation of complex-shaped long items with a big ratio between a length and a cross dimension
die forging of porous billets without using of die tooling
high purity of a filtering material in terms of extraneous impurities due to the absence of a plasticizing agent, a pore agent, etc. in a fusion mixture
low steel and labor intensity of production of tool equipment
MAGNETIC PULSE PRESS ELECTROHYDROPULSE PRESS
The technology and equipment of magnetic pulse treatment of materials is designed for the performance of cutting and piercing of sheet metallic and non-metallic materials without using conventional die tooling
PROCESSED MATERIALS
copper, aluminum, magnesium and their alloys, low-carbon steel
TYPES OF TECHNOLOGICAL OPERATIONS
cutting, piercing, molding, embossing, grooving and shallow drawing of sheet blanks
swaging, bulging, cutting, hole punching, deflanging, expansion, making of permanent and flexible joints on items made of tubular billets
crimping of cable lugs, wires and cables
electrodischarge formation and sintering of metallic powders
electrohydropulse formation of flares in grounds and boreholes for bored piles and anchors
APPLICATION
enterprises of automobile, aircraft and instrument industries, mechanical engineering and powder metallurgy, process lines for filling, packing and sealing in chemical, food and medical industries, construction of pile foundations; removal of foundry slags; dispersion of solid materials
MAGNETIC-PULSE TREATMENT
High-speed magnetic-pulse surface treatment of metal products. Under the effect of a strong pulsed electromagnetic field, specific structural and phase transformations occur in the metal, as a result of which the physical properties of the material change, defects in the crystal lattice are eliminated, internal stresses of product are stabilized. As a result of magnetic-pulse treatment, the strength and wear resistance of highly loaded critical products and tools that are used in various industrial fields increase. Treated materials: steel, non-ferrous metals and alloys (titanium, bronze, duralumin), hard-alloy metals
TECHNICAL CHARACTERISTICS
maximum accumulated energy, kJ (15 (MIP-18) / 8 (MIU-3)
maximum operating voltage, kV (13,3 (MIP-18) / 6,0 (MIU-3)
storage capacity, μF (180 (MIP-18) / 450 (MIU-3)
power consumption under AC mains with a voltage of 220 V, a frequency of 50 Hz, no less than (VA) (3000 (MIP-18) / 3000 (MIU-3)supply mains voltage, V (220 (MIP-18) / 220 (MIU-3)
products and tool operating at high loads, including shock ones, and increased abrasive wear, applied in machine building, woodworking, forestry, agriculture, food and other industries
ADVANTAGES
high technological flexibility: it is possible to treat various details with different sizes and configuration using one inductor and obtain optimal changes in required metal properties, fluently managing with processing energetic parameters
simplicity of technological equipment manufacture
low cost of the technology and equipment in comparison with the equipment, used in most modern surface hardening methods of surface hardening
permanence of the product shape and properties, quality improvement of the hardened surface after magnetic pulse treatment
high manufacture culture and simple equipment service due to the ecologically safe treatment and also absence of corrosion environment and waste
the process can be automated, that provides high efficiency
CLOSE
INDUCTION HEATING
ENERGY-EFFICIENT INDUCTION HEATING TECHNOLOGIES
Main directions: simulation, design and development of energy efficient technologies of induction heating; development and production of automated complexes of induction heating; development and production of auxiliary induction heating equipment, tooling and control systems; modernization, repairing and adjustment of induction heating equipment
APPLICATION
through heating of rods, tubes, rings and bands of various geometry for hot forging, upsetting, rolling; face hardening of various engineering parts: axles, pins, plugs, shafts gears, plates, machine stands; melting of metals before teeming; brazing of cutting tools. Equipment and technologies are used at PTI NAS of Belarus and at large machine-building enterprises of the country and neighboring countries
ADVANTAGES
high productivity
technical simplicity
availability of full automation
low deformation of parts, absence of calx and decarbonization
high efficiency coefficient (no less than 95%)
electricity saving (no less than 30%)
return on investment just due to electricity saving (no more than 3 years)
eco-friendliness
certificate of own production
declarations of compliance with the requirements of the Customs Union
technologies and equipment comply with the technological mode V
comformity certificate ISO 9001 STB, SMK
CALCULATION, ENGINEERING AND PRODUCTION OF INDUCTORS
Accurate calculation and design of inductors are important for obtaining high-quality heat treatment of parts. Obtaining the optimal combination of properties (hardness, strength and layer configuration) allows to increase the service life of critical parts operating under banding, alternating and other loads
Specialists of PTI NAS of Belarus have created versatile methods for simulation and calculation of the electromagnetic field distribution during induction heating for heat treatment operations, metal heating for deformation, soldering and melting
INDUCTOR MODELS
The catalog and unique constructional design techniques have been created in various software products of inductors for surface hardening of various parts
Construction of the inductor is adapted to each specific part depending on the material and conditions of its operation. Exact inductor configuration ensures optimal heating mode and maximum productivity of the induction equipment increasing its efficiency factor and energy efficiency of hardening technology
CLOSE
SURFACE PHENOMENA
MAGNETIC FIELDS ASSISTED FINISH MACHINING USING ABRASIVE MEDIA
Magnetic abrasive machining of parts made of steels and alloys for the achievement of high roughness classes with an equilibrium microrelief of surfaces and increase of mechanical properties of the outer layer
TECHNICAL CHARACTERISTICS
the surface roughness changes from the initial value of 0.8–1.2 µm to Ra=0.04–0.2 µm within 30–100 seconds, from 1.6–3.2 µm to Ra=0.1–0.8 µm within 60–120 seconds. Microhardness of the outer layers of steel parts increases by 10–25 %
APPLICATION
products of mechanical engineering and electronic industry, cutting and deforming components of devices
ADVANTAGES
treatment of bodies of revolution and complex profile parts within one setup
treatment in one pass of prefabricated parts made of dissimilar materials
simultaneous roughness (by 2-4 classes) and microhardness (by 10-25%) increase of processed surfaces
WORKED-OUT DIAMOND TOOL RECOVERY
Energy-efficient recovery technology of diamond crystals from worked-out tools
APPLICATION
recycling of diamonds
ADVANTAGES
License of General Directorate of Precious Metals and Precious Stones of the Ministry of Finance of the Republic of Belarus № 02200/21-00108
DIAMOND-ABRASIVE COMPOSITE MATERIALS FOR TOOL PURPOSES, PRODUCTION TECHNOLOGY OF GRINDING AND DIAMOND DRESSING TOOLS, METHODS OF TESTING AND CERTIFICATION
Diamond-abrasive materials based on polymer, metal and metal-ceramic bonds, technology of batch mixture preparation, molding (briquetting) and energy-efficient sintering
TECHNICAL CHARACTERISTICS
hardness on polymer bonds, HB (60…95)
sSintering temperature, °С (160–180)
hardness on metal bonds, HB (70…105)
sintering temperature, °С (740–780)
APPLICATION
tools for treatment of metals, glass, superhard materials and diamonds
ADVANTAGES
increase of productivity and quality of treatment
reduction in costs related to realignment of equipment
reduction in energy consumption
tool life increase in 1,2-3 times depending on processing material
money saving
TEST BENCHES FOR INSPECTION OF GRINDING WHEEL SAFETY
Test benches for inspection of safety and mechanical strength of abrasive and diamond wheels of circular cutoff saw with a diameter of 80–1200 mm
TECHNICAL CHARACTERISTICS
automatically programmed cycle testing at modes up to 150 m/s
APPLICATION
mechanical engineering; glass processing; tooling industry; furniture and other industries; testing and certification of tools
ADVANTAGES
complete with certification normative documents stipulated by the Gosstandart of the Republic of Belarus
modern element base
low content of metal
continuous control over a revolution rate of the drive
ROTARY CUTTING TOOL
High-production treatment by lathe turning and milling of parts with hardness up to 54–56 НRC
treatment of parts with hardness up to 56 НRC, assembled imbricated cores, high-filled composite materials, parts fixed by deposit welding, glass-fiber materials and other materials, treatment of steels, titanium and heat-resistant alloys, aluminum alloys, high-strength cast irons, ceramics, weld deposits, calender rolls, papermaking rolls
ADVANTAGES
production efficiency is increased by 2–5 times at lathe turning and by 5–20 times if grinding is replaced
CLOSE
APPLIED MECHANICS
SETTLEMENT AND ANALYTICAL SUPPORT OF ACCIDENT AND INCIDENT INVESTIGATIONS AT HAZARDOUS AND POTENTIALLY HAZARDOUS OBJECTS
Analytical calculations
verification analysis of strength and stability
analysis of the residual strength of vessels, main pipelines, industrial pipelines with various defects, including the finite element method in elastic and plastic zones
cyclic strength analysis
analysis of brittle fracture resistance
analysis of stressed state of parts of detachable (flange) joints, modes of torque studs
residual life analysis
Analytical research methods
establishment of an actual operating model of destroyed constructional element of research object
actual level determination of defectiveness and fracture zone
numerical simulation of the power actions complex
actual characteristic determination of metal mechanical properties in fracture zone and away from it
strength calculations with an evaluation of limit conditions of the emergency facility including finite element method
development and issuance of conclusion about the causes of destruction and failures
development of technical solutions and recommendations for the subsequent accident-free operation of similar objects
OBJECTS FOR TECHNICAL CONDITION RESEARCH AND RESIDUAL RESOURCE ESTIMATION
List of technical devices and objects from accreditation scope
pressure vessels
main-gas-, oil and product pipelines
technological equipment and industrial pipelines
tanks for storing oil, oil products
pump-compressor equipment
fuel pipelines
DIAGNOSTICS OF HAZARDOUS AND POTENTIALLY HAZARDOUS INDUSTRIAL OBJECTS BY NON-DESTRUCTIVE CONTROL METHODS
RESEARCH DESCRIPTION
Optical control
visual method
visual examination and measurements
Control of penetrating substances
liquid penetrant inspection
Acoustic control
ultrasonic inspection, echo method
ultrasonic thickness measurement, echo method
Material control
hardness change by portable hardness testers of static and dynamic types of action according to Brinell, Rockwell, Vickers
