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Registration Number

0225U004262, (0124U003940) , R & D reports

Title

Synthesis of diamond-containing composites through thermodeformation laser sintering for abrasive machining of large components in aerospace, shipbuilding, and machinery industries.

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Синтез абразивовмісних композитів термодеформаційним лазерним спіканням та виготовлення інструменту на їх основі

Head

Voloshko Svitlana M., д.ф.-м.н.

Registration Date

27-11-2025

Organization

National Technical University of Ukraine «Igor Sikorsky Kyiv Polytechnic Institute»

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Enhancing the effectiveness of abrasive machining of large components in aerospace, shipbuilding, and machinery industries through laser synthesis of composites containing synthetic diamonds (SD) or other superhard materials (SHM) and the use of a new tool design based on the synthesized materials.

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A fundamentally new process has been developed – thermal deformation laser sintering (TLS) – for the synthesis of composite layers with superhard materials (synthetic diamonds, cubic boron nitride). This process is universal, as it allows to manufacture single or multilayer abrasive tools with flat, cylindrical and shaped surfaces, and it is also flexible - the tool can have both simple and complex configurations, be used for processing products made of polymeric materials (carbon, glass, and organ fiberglass) and steels of various classes. The proposed scheme and technological principles for implementing TLS are the most appropriate from a technological and economic point of view. This is due to the combination of experimental and theoretical studies to establish cause-and-effect relationships between the technological parameters of TLS and the dimensional and physical-mechanical characteristics, structural and phase state of the synthesized composites. A new original design has been patented and an experimental sample of an abrasive tool in the form of a hollow cylinder has been manufactured, on the outer surface of which replaceable inserts with an abrasive TLS layer are located. Traditional tools wear out quickly, so they need to be replaced frequently, which increases equipment downtime. The developed tool has increased wear resistance and can have a larger working area. The use of TLS for the manufacture of tools on metal bonds allows for significantly higher process productivity – up to 100 mm2/min, compared to traditional methods (electroplating, bulk sintering). Additional advantages of TLS include the ability to programmatically place abrasive grains on the working surface and thereby reduce diamond consumption by ~10 times, as well as increase the strength of their adhesion to the metal bond by ~20 times. The developed tool is intended for abrasive processing of large-sized sheet products used in strategic industries – aircraft, shipbuilding and mechanica

Product Description

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Leonid F. Golovko
Andrii P. Burmak
Oleksii O. Goncharuk
Kahliak Oleksii D.
Oleksandr O. Danyleiko

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2025-11-27