Marina A. Volosova

Moscow State Technological University Stankin · High-efficiency ptocessing technologies

The surface of ceramic products manufactured using diamond grinding is replete with shallow scratches, deep grooves and other defects. The thickness of the defective layer amounts to 3–4 µm and it must be removed to increase wear resistance of the products when exposed to intense thermomechanical loads. In this study, removal of the defective layer...

Thermomechanical action during high-performance diamond grinding of sintered cutting Al2O3/TiC and SiAlON ceramics leads to increased defectiveness of the surface layer of the deposited TiZrN and CrAlSiN/DLC coatings. It predetermines the discontinuous and porous coatings and reduces its effectiveness under abrasive exposure and fretting wear. The...

This work is devoted to the study of the interelectrode gap’s condition during wire electrical discharge machining. The experiments were carried out on workpieces made of chromium-nickel anti-corrosion steel 12Kh18N10T and duralumin D16 with a brass tool CuZn35 with a diameter of 0.25 mm in deionized water. The developed diagnostic tool based on vi...

The influence of Cr-Al-Si-N, DLC-Si, and Cr-Al-Si-N/DLC-Si thin coatings deposited on titanium alloy (Ti-Al-Zr-Sn-Nb system) samples with different surface reliefs on wear resistance under abrasion and fretting conditions was investigated. The influence of coatings on the initial microrelief after finishing milling and lapping with micro-grained ab...

There are two main ways of carrying out the electrical discharge machining of the insulating ceramics: changing the electrical and chemical properties of ceramics due to additives in producing composites/nanocomposites and changing the electrical and chemical properties in the interelectrode gap. This review summarizes and analyzes the current data...

Modern machine-building production equipped with high-performance mechatronic systems and numerically-controlled and adaptive control machines for blade cutting of heat-resistant chromium-nickel and titanium alloys requires increasing the operating properties of cutting tools working at high temperature-force loads in the contact zone, respectively...

Micro-milling is widely used to make micro-channels in various fields. In this study, micro-milling of rectangular bronze microchannels was carried out with carbide end mills with a diameter of 1 mm, processed with fast argon atoms, and coated with anti-friction wear-resistant titanium diboride. It was shown that the removal of a 3 µm thick surface...

The paper considers the possibility of replacing the process of conventional vacuum brazing of a molybdenum plate on carbon steel using copper brazing with the process of laser-directed energy deposition of domestically produced molybdenum powder. The research task is motivated by the demand for removing low-melting copper brazing from molybdenum c...

This paper is devoted to the problem of wear resistance in square Si3N4 ceramic cutting inserts, which exhibit high hardness and strength, in combination with brittleness, in machining super alloys (e.g., a nickel-based alloy of Inconel 718 type) for aviation purposes, when subjected to increased mechanical and thermal loads. Microtextures were pro...

The main regularities of influence of two-coordinate pulsed laser treatment parameters on processes of ablation and structural modification of Al 2 O 3 ‒TiC ceramics were established. The ambiguous influence of laser treatment parameters mode on the intensity of the ablation process was revealed. It was shown that structural modification nature is...

The influence of pulsed laser modification of nitride ceramics surface layer on the milling cutters reliability during the finishing of hardened steel workpieces was revealed. An increase in milling cutters reliability with modified cutting inserts was associated with the removal of defective layer formed during grinding and the formation of new su...

Wear-resistant coatings improve the machining capability of cutting tools and extend their useful life. However, when a tool needs to be reused, it is mandatory to remove the existing coating to facilitate resharpening and recoating. The existing technique uses electrochemical stripping, which is hazardous to the environment. The environmentally fr...

Coatings with a thickness from ~40 to ~50 µm on Ti6Al4V titanium alloys were formed by plasma electrolytic oxidation (PEO) in a silicate-hypophosphite electrolyte with the addition of graphene oxide. The PEO treatment was carried out in the anode–cathode mode (50 Hz) at a ratio of anode and cathode currents of 1:1; their sum density was 20 A/dm2, a...

DLC coatings have low adhesive bond strength with the substrate and a high level of residual stresses. This paper is devoted to researching a complex of characteristics of a DLC-Si coating deposited on samples of SiAlON ceramics with intermediate coatings (CrAlSi)N pre-formed to improve the adhesive bond strength employing vacuum-plasma spraying. D...

Coatings with a thickness from ~40 to ~50 µm on Ti6Al4V titanium alloy were formed by micro-arc oxidation in a silicate-hypophosphite electrolyte with additions of graphene oxide. Micro-arc oxidation treatment was carried out in the anode–cathode mode (50 Hz) with a ratio of anode to cathode currents of 1:1, a total density of 20 A/dm2, and a treat...

Nickel alloy high-speed processing technology using ball-end mills is characterized by high contact temperature and leads to accelerated tool wear. One of the effective ways to increase its reliability and service life is to modify the surface by applying functional antifriction layers in addition to wear-resistant coatings. Diamond-like carbon is...

SiAlON is one of the problematic and least previously studied but prospective cutting ceramics suitable for most responsible machining tasks, such as cutting sophisticated shapes of aircraft gas turbine engine parts made of chrome–nickel alloys (Inconel 718 type) with increased mechanical and thermal loads (semi-finishing). Industrially produced Si...

Theoretical and experimental research of thermal phenomena during blade cutting machining by tools with multilayer composite coatings has been carried out. The calculation scheme and analytical dependence are presented, the character of heat fluxes distribution in cutting zone at application of wear-resistant coatings is established. Thermal-physic...

The paper presents the results of theoretical and experimental research of tribotechnical characteristics (tool wear on the back surface, tool durability period, critical cutting path length before blunting) of innovative nanostructured multilayer composite coatings on the tool for milling heat-resistant alloys of aerospace parts.

The paper considers the possibility of obtaining multicomponent coatings of a given composition and required thickness by magnetron sputtering on the basis of controlling the stoichiometry of the target cathode used. A toolkit for preliminary estimation of thickness and stoichiometry of multicomponent coatings synthesized by magnetron sputtering ta...

The paper aims to extend the current knowledge on electrical discharge machining of insulating materials, such as cutting ceramics used to produce cutting inserts to machine nickel-based alloys in the aviation and aerospace industries. Aluminum-based ceramics such as Al2O3, AlN, and SiAlON are in the most demand in the industry but present a scient...

The work is focused on the combined process of obtaining bimetallic parts that involve laser-directed energy deposition (LDED) additive technology and the conventional casting process. In this research, molybdenum powder was deposited by LDED on a cast 25L steel substrate. The choice of materials is motivated by demands for replacing the traditiona...

The results of studying a beam source of fast argon atoms obtained by neutralizing charges of accelerated ions during their flight through an accelerating grid in the form of a set of plane–parallel plates are presented. Ions are accelerated from the plasma emitter by a voltage of negative polarity at the grid, fly into the gaps between its plates,...

To improve the quality of a part manufactured by the additive method, it is necessary to eliminate the porosity and high roughness of its surface, as well as to deposit a coating on it. For this purpose, in the present work, we studied the combined processing in a gas discharge plasma of complex shape parts obtained by the additive manufacturing me...

Significance of AlN and TiN coatings for controlled transformation of stress state of Si3N4–TiC ceramic surface layer under the force loading conditions is analyzed. It was found that the TiN coating has a more favorable effect on the stress state of ceramic structural elements, while the AlN coating more positively affects the stress state of the...

Peculiarities of the effects of AlN and TiN coatings on the thermal and stress state of the surface layer of Si3N4–TiC ceramics under heat-flow conditions were studied. It was found that the TiN coating had a more favorable effect on the stress state of the ceramic structural elements; the AlN coating, on the stress state of the boundary between th...

The developed methodological approach to ensuring the operational stability of ceramic tools, based on creation of functional surface layer after removing defective surface layer formed after grinding is presented. The advantages of functional surface layer on ceramic tools are confirmed by tests. Ill. 3. Ref. 28.

The specific features of the destruction of tool ceramics, associated with structural heterogeneity and defects formed during diamond grinding, largely determine their reduced reliability (dispersion of resistance). This is most pronounced at increased heat and power loads on the contact surfaces and limits the industrial application of ceramic cut...

Peculiarities of effect of AlN and TiN coatings on the thermal and stress state of the surface layer of Si 3 N 4 ‒TiC ceramics under heat flow conditions are studied. It was found that TiN coating has a more favorable effect on stress state of the structural elements of ceramics, and AlN coating ― on stress state of the boundary between the coating...

Aluminum-based ceramics are used in industry to produce cutting tools that resist extreme mechanical and thermal load conditions during the machining of Ni-based and high-entropy alloys. There is wide field of application also in the aerospace industry. Microtexturing of cutting ceramics reduces contact loads and wear of cutting tools. However, mos...

Aluminum-based ceramics exhibit excellent wear resistance and hot hardness that are suitable for various responsible applications allowing products to work under extreme mechanical and thermal loads (up to 1000 °C). The problem of high-precision forming complex-shaped parts is a known engineering challenge due to the insulating properties of alumin...

Today, laser processing is becoming more and more relevant due to its fast adaptation to the most critical technological tasks, its ability to provide processing in the most rarefied and aggressive mediums (e [...]

Complete correlation between dimensions of the wear area on specimens made of oxide-carbide ceramics and the root-mean-square value of vibration acceleration in frequency ranges 2 – 4, 5 – 8, 10 – 16 kHz during frictional interaction with a steel disk is established using the procedure developed. The relationship revealed is recommended for develop...

The results of force, thermal, and combined stress analysis of the surface layer of Al2O3–TiC-ceramics with AlN and TiN coatings are analyzed and systematized. The established relationships are used to create a new generation of ceramic cutting tools with an expanded field of application

The article is devoted to the compressive review of the defects observed in the products of the machinery usage made mainly of anti-corrosion steels of the martensite-austenite group, difficult to process materials such as pure titanium, nickel, and their alloys, super and high entropy alloys and triple fusions produced by laser additive manufactur...

A uniform distribution of power density (energy flux) in a stationary laser beam leads to a decrease in the overheating of the material in the center of the laser beam during laser powder bed fusion and a decrease in material losses due to its thermal ablation and chemical decomposition. The profile of the uniform cylindrical (flat-top) distributio...

This research aimed at an increase in wear resistance of round cutting plates manufactured with SiAlON dielectric ceramics through deposition of wear-resistant coatings. To increase effectiveness of the coatings, their adhesion was improved by the removal of defective surface layers from the cutting plates before the deposition. As the depth of cav...

The main purpose of this paper was to study the efficiency of using diamond-like carbon (DLC) coatings based on a-C:H:Si with a pre-formed CrAlSiN sublayer to increase the cutting ability of ball end mills made of KFM-39 cemented carbide at a speed of 150–250 m/min in milling aircraft-grade Inconel 718, and to assess the DLC coating effect on the q...

The article deals with the properties of the Ti-TiN-(Ti,Cr,Al)N multilayer composite coatings with a nanolayer structure of their wear-resistant layers and the nanolayer period λ within a range from 10 to 900 nm. The studies were focused on the coating nanostructures and the influence of the nanolayer period λ on the performance properties of coate...

The paper presents the results of a study of one of the ways to improve the wear resistance of “duplex” coatings applied to cutting tools, which are due to preliminary ion nitriding, involving nitrogen saturation of the tool surface by diffusion method with the possibility of physical deposition of the main wear-resistant coating — (Ti,Cr)N. In add...

The results of experimental research of tribotechnical characteristics of cutting tools with different wearresistant coatings during milling treatment of titanium alloys are presented. On the basis of the analysis of the obtained results the positive influence of TiB2 as a part of the combined coating on the wear resistance of the cutting tool is e...

The influence of AlN and TiN coatings on the stress–strain state of the surface layer on Al2O3–TiC ceramics under the influence of a combined load is analyzed. The regularities of stress distribution and the location of microstructural stress concentrators forming the surface layer of this ceramic are established.

Regularities of the influence of AlN and TiN coatings on the stress–strain state of the surface layer on Al2O3–TiC ceramics structural elements under the influence of heat flow are established. The formation of microstructural stress concentrators at the boundary of AlN and TiN coatings with the initial ceramics is revealed.

Regularities of stress-strain state of surface layer of Al 2 O 3 ‒TiC-ceramics with AlN and TiN coatings under the action of force load are established using the methodology of computer engineering. The features of influence of AlN and TiN coatings on the nature of changes in the stress intensity in the surfaces of structural elements forming the s...

The article describes the results of the investigation focused on the properties of the Zr,Hf-(Zr,Hf)N-(Zr,Hf,Me,Al)N coatings, where Me means chromium (Cr), titanium (Ti), or molybdenum (Mo). These coatings have three-layer architecture, including adhesion, transition, and wear-resistant layers, while the latter, in turn, has a nanolayer structure...

Установлены основные закономерности напряженного состояния поверхностного слоя шлифованной Si 3 N 4 ‒TiC-керамики под действием комбинированной нагрузки. Выявлена специфика формирования структурной неоднородности напряжений и микроструктурных концентраторов напряжений, приводящих к изменению структуры керамики за счет образования несплошностей.

The regularities of influence of AlN and TiN coatings on stress-strain state of Al 2 O 3 ‒TiC ceramics structural elements, which forming its surface layer, under influence of heat flow are established. The formation of microstructural stress concentrators at the boundary of AlN and TiN coatings with the initial ceramics is revealed.

The field of applied wire electrical discharge machining (WEDM) is rapidly expanding due to rapidly increasing demand for parts made of hard-to-machine materials. Hard alloys composed of WC, TiC and Co are advanced cutting materials widely used in industry due to the excellent combination of hardness and toughness, providing them obvious advantages...

By using the methodology of computer engineering, we establish the regularities of the stress-strain state of the surface layer of Al2O3–TiC ceramics with AlN and TiN coatings under the action of force loads.We determine the specific features of the influence of AlN and TiN coatings on the character of changes in the stress intensity on the surface...

We systematize the results of force, thermal, and combined analyses of the stress-strain state of the surface layer of ground Si3N4–TiC-ceramics. The relationships obtained as a result of competent ordering of the data of numerical experiments are recommended for the creation of innovative tools made of silicon-nitride ceramics with regard for the...

As a result of investigation of the nature of changes in the profile of the working surface of a diamond wheel in the process of grinding of high-density Al2O3–TiC ceramics, we establish the principal mechanisms of destruction of diamond grains and formation of a layer of sludge on the grains and in the binder. We analyze the influence of these cha...

he resistibility to corrosion of biocompatible metals is significantly reduced when plastic deformation of the surface layer is more than 0.5%. To increase the successful reliability of consolidation of bone tissues is proposed to use implants made of chemically pure titanium with a nanostructured biocompatible Ti-TiN coating to improve functional...

A new approach to obtaining three-dimensional cutting edges on a tapered cutting surface is proposed based on an imageobtained on a measuring machine in the control section. The method is developed based on forming a spline and evaluatingthe shape using a unique algorithm, which is in turn based on an analytical mathematical model. The developed me...

The paper discusses the influence of the thickness of nanolayers in a wear-resistant layer of the Ti-TiN-(Ti,Cr,Al)N multilayered composite coating on the coating and tool cutting properties in turning 1045 steel. The coatings with nanolayer thickness in the range of 10–302 nm were investigated. The studies showed that with a decrease in the nanola...

With the help of the main concepts of computer engineering, we study the thermal and stressed state of the surface layer of ground Si3N4–TiC ceramics of four systems subjected to the action of heat flows. We analyze the regularities of temperature and stress distributions in six selected surfaces of the surface layer. We also determine specific fea...

The paper proposes a classification of adaptive materials and coatings for tool purposes, showing the ability to adapt to external heat and power influences, thereby improving tool life. Creating a cutting tool made of composite powder high speed steels containing refractory TiC, TiCN, and Al2O3 compounds for milling 41CrS4 steel demonstrated the e...

A feature of radiation-beam technologies is similar processes associated with phase transformations and chemical reactions that cause changes in the volume of matter, accompanied by the vibroacoustic energy release distributed through the equipment flexible system in a wide frequency range (up to 40 kHz and high for 150 ms). The vibroacoustic signa...

Ceramics are widespread materials for engineering applications due to their properties, such as low wear resistance and coefficient of thermal expansion. The high hardness and brittleness of ceramics reveal their difficulties in traditional machining. Electrical discharge machining is induced to be a method for machining non-conductive ceramics in...

We establish the main regularities of the stressed state of the surface layer of ground Si3N4–TiC ceramics under the action of combined loads. We also reveal specific features of the formation of structurally inhomogeneous stresses and microstructural stress concentrators affecting the structure of the ceramics as a result of the formation of disco...

The material removal mechanism, submicrostructure of surface and subsurface layers, nanotransformations occurred in surface and subsurface layers during electrical discharge machining two structural materials such as anti-corrosion X10CrNiTi18-10 (12kH18N10T) steel of austenite class and 2024 (D16) duralumin in a deionized water medium were researc...

The mechanism of the material destruction under discharge pulses and material removal mechanism based on the thermochemical nature of the electrical erosion during electrical discharge machining of conductive materials were researched. The experiments were conducted for two structural materials used in the aerospace industry, namely austenite antic...

The study’s purpose is to determine the rational Si content in the DLC-Si external layer of (CrAlSi)N/DLC-Si coatings deposited on α/β-SiAlON + TiN ceramics. The influence of Si content on physical and mechanical properties of coatings such as microhardness, modulus of elasticity, and friction coefficient, and wear resistance of solid ceramic end m...

Small-size cutting inserts for assembly cutters are widely used to manufacture a variety of parts for the aerospace, automotive and mechanical engineering industries. Due to their high hardness and chemical stability, cutting Al2O3-TiC ceramics significantly outperform hard alloys in machining heat-resistant and difficult-to-machine materials. Howe...

The study is devoted to the development and testing of technological principles for the manufacture of solid end mills from ceramics based on a powder composition of α-SiAlON, β-SiAlON, and TiN additives, including spark plasma sintering powder composition, diamond sharpening of sintered ceramic blanks for shaping the cutting part of mills and depo...

The results of computer simulation of thermophysical phenomena in the contact zone during blade cutting of metals with multi-layer composite wear-resistant coatings that ensure the adaptability of the cutting wedge to friction conditions are presented. On-site experimental studies of the cutting temperature during turning with various coatings, str...

Additive manufacturing has evolved over the past decades into a technology that provides freedom of design through the ability to produce complex-shaped solid structures, reducing the operational time and material volumes in manufacturing significantly. However, the surface of parts manufactured by the additive method remains now extremely rough. T...

The results of force, thermal, and combined analyses of the stress-strain states of the surface layers of Al2O3–TiC ground ceramics are systematized. The relationships obtained as a result of the systematic analysis serve as a basis for the refinement of the physical models of fracture of the products made of Al2O3–TiC ceramics in the course of ope...

On the basis of the main concepts of computer engineering, we study the stressed state of the surface layer of ground Si3N4–TiC ceramics subjected to the action of force loads. The formation of microstructural stress concentrators at the point of application of concentrated forces is discovered. These concentrators lead to changes in the structure...

We determine the principal regularities of the stressed state of the surface layer of Al2O3–TiC ground ceramics under the action of combined loads. It is discovered that the force load compensates the thermal elastic strains but, at the same time, complicates the stressed state as compared with the action of loads of the same type. We clarify the r...

The main elements of the working surface of the diamond wheel after grinding Al2O3–TiC-ceramics are revealed and their parameters are investigated. Using the developed technique, topographic maps, projections of grains, and transverse and integral profiles for the selected sections of the working surface of the diamond wheel were constructed. A met...

С использованием базовых положений компьютерной инженерии изучено тепловое и напряженное состояние поверхностного слоя шлифованной Si3N4‒TiC-керамики четырех систем под действием теплового потока. Установлены закономерности распределения температур и напряжений в шести выделенных поверхностях поверхностного слоя. Определена специфика формирования с...

С использованием базовых положений компьютерной инженерии изучено напряженное состояние поверхностного слоя шлифованной Si3N4‒TiC-керамики под действием силовой нагрузки. Выявлено формирование микроструктурных концентраторов напряжений в точке приложения сосредоточенной силы, приводящих к изменению структуры керамики за счет образования несплошност...

An effective approach for preparing electrically conductive multiscale SiAlON-based nanocomposites with 10 wt.% and 20 wt.% of titanium nitride was developed. Fully dense samples were obtained by spark plasma sintering (SPS) at 1700 °C and 80 MPa for 30 min. The morphology of nanocomposites was observed using scanning electron microscopy and the ef...

The chapter focuses on new ways of improving the efficiency of cutting steels with the use of nanodispersed multilayered composite coatings and diamond-like carbon coatings deposited on cutting tools of ceramics by innovative arc-physical vapor deposition processes with filtration of vapor-ion flow. Three-layered architecture was used in nanostruct...

The paper considers the properties of the Cr,Mo-(Cr,Mo)N-(Cr,Mo,Al)N, Zr,Nb-(Zr,Nb)N-(Zr,Nb,Al)N, and Cr,Mo-(Cr,Mo,Zr,Nb)N-(Cr,Mo,Zr,Nb,Al)N coatings with wear-resistant layers of a nanolayer structure. The structures and compositions of the coating were investigated using a transmission electron microscope (TEM). The cutting tests in the longitudi...

The paper is devoted to the research of the effect of ultrasonic postprocessing—specifically, the effects of ultrasonic cavitation-abrasive finishing, ultrasonic plastic deformation, and vibration tumbling on surface quality, wear resistance, and the ability of real aircraft parts with complex geometries and with sizes less than and more than 100 m...