Registration Number
0226U002281,
(0124U000553)
, R & D reports
Title
Development of technology and equipment for cold spraying of restorative coatings on aircraft parts.
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Комплексні дослідження процесів напилювання покриттів.
Head
Shorinov Oleksandr V., Кандидат технічних наук
Registration Date
12-02-2026
Organization
National Aerospace University "Kharkiv Aviation Institute"
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Definition of the scientific and technical basis for the development of technology and equipment for cold spraying of coatings with improved physical and mechanical characteristics and the powder utilization rate for the restoration of damaged parts of aircraft engines by increasing the initial parameters of the working gas.
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The object of the study is the process of forming restorative coatings using cold gas dynamic spraying on aircraft engine parts. The aim of the research is to enhance the physical and mechanical properties of the coatings and improve deposition efficiency by developing optimized equipment and technological regimes with elevated working gas parameters. During this stage, an integrated scientific approach to supersonic nozzle design was developed and implemented, combining a one-dimensional isentropic model, multi-criteria optimization, and numerical CFD modeling. This enabled the design and fabrication of a series of high-efficiency nozzles, specifically a specialized rotating nozzle for the treatment of internal and hard-to-reach surfaces of aircraft engine components. Experimental prototypes of ohmic heaters were designed and manufactured, capable of maintaining a stable gas temperature of up to 700 °C at pressures up to 4.0 MPa. Experimental results demonstrate that increasing the working gas pressure to 1.0–2.5 MPa, in conjunction with an optimized nozzle geometry, results in a nearly threefold increase in deposition efficiency. The resulting metal-ceramic coatings based on Ni, Al, and Zn exhibit a dense microstructure with porosity below 1.5%, along with a 20–30% increase in adhesive strength and microhardness compared to standard low-pressure counterparts. An automated process control system based on CNC controllers was developed to ensure high stability and reproducibility of the spraying results. Technological recommendations were formulated for selecting optimal restoration regimes for gas turbine engine casing parts made of titanium and aluminum alloys. The research results have been implemented at Motor Sich JSC and Ivchenko-Progress JSC, as confirmed by implementation certificates. The developed solutions significantly reduce repair costs and extend the service life of critical aircraft engine components.
Product Description
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Abashyn Serhii L.
Volkov Andrii O.
Nina V. Savchenko
Kurina Nina
Serhii Nyzhnyk
Sveshnikova Valentyna H.
Oleksandr V. Shorinov
Oleksii V. Bondarenko
Stanislav S. Dziuba
Ihor V. Zorik
Roman S. Ipatov
Mykola Y. Kalinichenko
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2026-02-12
