MAI graduate invented the laser technology to make the plane stronger

Daniil Korolev, the 2020 graduate of the Department 208 "Electric rocket engines, power and energy-physical powerplants" of the Moscow Aviation Institute, is the author of innovative project on laser shock hardening, which in 2020 received support and funding under the "UMNIK" program from the innovation assistance Fund.

The idea of the project is aimed at solving the problem of strength of a highly loaded part of an aircraft engine or an aircraft. During the operation, aircraft parts are constantly subjected to alternating loads. The metal begins to accumulate damage, which over time is transformed into cracks. All this results into spending on aircraft repairs, and also increases risk of accidents.

The young scientist suggested that at the manufacturing stage, the aircraft part should be subjected to laser hardening to make it more durable and reduce the likelihood of cracking.

"The part is pre-treated with special coating that absorbs radiation. Then short laser shots are fired, they affect the part like hammer strikes. As a result of this manipulation, the properties of the surface layer (one millimeter from the surface) change — it becomes stronger and able to withstand more cycles, it also becomes less exposed to corrosion and wear. It is less likely that there will be microcracks that will lead to destruction". — says Daniil.

There are three people in the team: the student 205 of the Department «Technology of production of aircraft engines» Gleb Kozhevnikov, with whom Daniel makes drawings, modeling, carries out the «laser-part» interaction model development. And tutors — the candidate of Technical Sciences, associate Professor of the Department 205 Maxim Lyakhovetsky and doctor of technical Sciences, Professor of the Department 205 Leonid Lesnevsky, who are also the ideologist of the project — it was he who suggested that Daniil should take up an interesting topic as a thesis, which is has not been yet studied in Russia.

The project has great potential. Currently the standard method of shot blasting is used in production, when small balls, about one millimeter, are emitted at a very high speed, and when they hit the surface of the product, they strengthen it. It is estimated that laser impact treatment will be more effective than shot blasting by 20-100% (depending on the type of metal).

"The competitive environment is represented by two companies located in the United States. At the same time, they do not have the opportunity to enter our domestic market due to restrictions on the import of high-power laser systems. There are no such companies in Russia, but the domestic industry is interested." — says Daniil.

The UEC-UMPO branch of the design Bureau named after A. Lyulka has already expressed its interest in the project. In case of successful implementation of the research work, the design Bureau is ready to consider the possibility of further investment in the development of a pilot plant.

At the same time, potential consumers include not only the aviation industry, but also the automobile industry, railway transport, shipbuilding, general engineering, and even nuclear power.

"The technology might be used wherever metal is experiencing alternating loads" — notes Daniil. "This includes shipbuilding, engine building, aircraft construction, space industry, automotive industry, medicine and much more."

At the moment, there is developed concept of laser system, preliminary market analysis conducted, the project’s implementation opportunities were evaluated, and the basic characteristics of the installation were calculated. Funding under the «UMNIK» program allowed us to continue work and to concentrate on the stage of laser shock hardening modes and the structural state of hardened samples research, samples testing, as well as the subsequent development of a digital layout of the plant. In the future, Daniil plans to apply for a patent, as well as to enter the «Start» program (aimed at creating and maintaining innovative microenterprise at the stage of first sales). According to optimistic calculations, the author of the project plans to reach market sales volumes approximately by 2024.