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Registration Number

0225U004228, (0124U003918) , R & D reports

Title

Development of practical recommendations for expanding the application of additive technologies for manufacturing parts and field repair of military equipment

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Дослідження зміцнюючо-оздоблюючих методів обробки натурних деталей. Розробка технологічних рекомендацій щодо розширення застосування адитивних технологій для виробництва деталей та польового ремонту військової техніки

Head

Dmytro V. Pavlenko, Доктор технічних наук

Registration Date

26-11-2025

Organization

Zaporizhzhya Polytechnic National University

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The main goal of the project is to increase the quality and load-bearing capacity of military parts and dual purpose products, manufactured by means of additive technologies (engine parts, transmissions, suspensions), as well as traditional machining technologies by cutting. Scientific and technical development is aimed at the creation of new technologies for the production and repair of products for defense needs under martial law.

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In response to critical wartime challenges and the urgent need for rapid restoration of military equipment components, the problem of increasing the operational reliability of additively manufactured products has been successfully solved. The research covered a wide range of dual-use materials: from structural polymers to high-tech aerospace alloys produced using FDM, SLS, and WAAM technologies. A key achievement in the polymer segment was developing a methodology to transform 3D-printed parts into fully functional assemblies. Systemic analysis of printing parameters enabled the construction of accurate mathematical models for predicting geometric dimensions. It was proven that optimized thermal annealing regimes guarantee increased strength, allowing FDM printing for loaded mechanisms, particularly magazine loading devices. In the metal segment, fundamental results were obtained on enhancing the fatigue life of critical elements like gas turbine blades. It was established that the service life of 3D-printed components is limited by surface defects. Ultrasonic shot peening significantly increased the high-cycle fatigue limit: by 105% for titanium aluminide alloy (SLS) and 60% for heat-resistant INCONEL 718. A significant achievement was resolving the "damping dilemma": while mandatory heat treatment reduces vibration damping, ultrasonic strengthening restores these properties by forming a unique dissipative layer. A unified technological route was formed and approved: "3D printing → thermal stabilization → vibro-polishing → ultrasonic strengthening". This opens the way for systemic implementation in repair units of the Armed Forces and Defense Industry of Ukraine, ensuring rapid return of equipment to service.

Product Description

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Dmytro V. Pavlenko
Daria V. Tkach
Natalia V. Gonchar
Dmytro M. Stepanov
Yevhen Vyshnepolskyi
Larysa O. Tumarchenko

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2025-11-26