- A methodology for the directed formation of the properties of the surface layers of products by accelerated flows of metallic plasma is proposed, based on a mutually consistent consideration of the processes of evaporation of the deposited material, transportation of erosion products and their deposition on the surface of a solid, thermal processes on the evaporated material and on the substrate, as well as plasma flow parameters.
- The basic laws of modification of the solid surface in the ion purification mode are determined, taking into account the cathode temperature, composition, spatial and temporal distribution of the generated erosion products, substrate temperature and gas pressure for various materials. The obtained dependencies allow you to control the process of spraying the surface, taking into account the size of the processed products and the duration of the process.
- It is established that the uniformity of the thickness of the coating applied from the metal plasma of the vacuum arc discharge can be controlled by changing the spatial configuration of the magnetic field in the area of the modified surface. A mathematical model is proposed and the principles of electromagnetic control of plasma flows for the formation of coatings with a given uniformity in thickness are developed.
- A mathematical model has been developed and analytical expressions have been obtained describing the penetration of plasma flow into cylindrical cavities and determining the uniformity of the thickness of the coating applied to the inner surface of the cylinder, including taking into account the flow of plasma flow around obstacles.
- To determine the flow rate of metallic plasma, which is one of the main factors determining the structure and properties of coatings, a mathematical model has been developed and analytical expressions based on the method of measuring plasma parameters using a single cylindrical probe have been obtained.
- For the first time, the possibility of controlling the thickness of coatings using compression layers arising in a plasma stream in front of an obstacle in its path is shown. The detected compression areas have a relatively small extent and obstacles are practically not observed at a distance of 3-4 cm from the surface.
- A mathematical model of the thermal regime of a metal rod eroded under the action of a vacuum arc discharge has been developed. Based on the mathematical expressions obtained, methods for stabilizing the temperature of the evaporator cathode are proposed, ensuring the stability of the properties and reproducibility of the coatings formed.
- For the first time in domestic and world practice, fundamentally new resource-saving environmentally friendly vacuum ion-plasma technologies based on vacuum-arc discharge for applying anti-emission coatings, such as Ti, Zr, Pt3Zr, etc., highly efficient specialized equipment for the implementation of these technologies have been developed and introduced into mass production of high-power generator lamps, which made it possible to master the production of strategically important for the state of products of increased reliability and durability, not inferior in their performance to the best world analogues. The developed technologies and equipment made it possible to produce powerful generator lamps in the right volumes, to abandon the use of toxic, fire and explosive substances, and to increase the percentage of yield of usable products. As a result of a comprehensive solution to the problem, the guaranteed durability of the lamps was increased by 3-4 times and amounted to 10000-12000 hours. The developments of IPME RAS employees have been introduced into serial production of about 60 types of generator lamps at the JSC “SED-SPb” (a subsidiary of AOOT “Svetlana").
- For the first time, a new technology based on vacuum-arc discharge and an installation for applying protective coatings of the CoCrAlY system to large-sized blades of stationary power gas turbines have been developed by order of industrial enterprises of St. Petersburg. The conducted studies have shown the advantages of vacuum-arc technology in comparison with other technologies. These include: a wide range of coating materials used; high adhesion strength of coatings to the base metal, which in certain conditions excludes the operation of diffusion annealing; the relatively low and adjustable temperature of the product during the application process, which makes it possible to abandon the recovery heat treatment; high utilization rate of the evaporated material; low energy consumption for evaporation; low cost of coatings; simplicity of equipment. High efficiency of application of such coatings as NiCrWTi and CoCrAlY-ZrO2/Y2O3 is shown.
- A new technology for applying pyrolytic carbon coatings to products has been developed, which relates to methods of plasma chemical deposition from the gas phase. The peculiarity is that the plasma of a vacuum arc discharge from a graphite cathode is simultaneously used both to heat the substrate and maintain its temperature at a given level, to clean it before coating, and to decompose gaseous hydrocarbons or vapors of liquid hydrocarbons into active radicals. For the first time, this technology has been used to apply the best anti-emission coating of pyrolytic carbon to the grid electrodes of high-power generator lamps.
- The mechanism of formation of carbon composite materials based on nanotubes, graphite and pyrocarbon, based on the decomposition of hydrocarbons under the action of vacuum-arc discharge plasma, has been experimentally investigated. Based on these compositions of carbon materials, a fundamentally new sorbent with unique sorption properties of heavy metals and radionuclides was obtained. The first assessment of the sorption characteristics of the new composite material under laboratory conditions showed almost complete filtration of elements such as lead and radionuclide 131I from an aqueous solution.
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