15 February 2016

Switching to the high-performance welding technology will provide benefits in terms of better product quality, reduced labor content, lower production cost and higher output. The first articles are already being mastered at the new Russian-made welding plant.

The advantage of electron beam welding is its ability to join parts made of high-alloy, difficult-to-weld metals. Welding at Aviaagregat’s new plant is carried out in high vacuum, which provides reliable protection of the weld pool and minimizes faulty welds.

In fact, welds produced by the electron beam welding process are so strong that when a welded part is loaded in tension the break occurs at the base metal rather than at the weld. This considerably increases the reliability and durability of critical aircraft components such as landing gears, which are Technodinamika’s primary products.

“A high degree of process automation and documentation is among the features of this equipment. The introduction of the welding plant helps eliminate a bottleneck in landing gear production,” says Technodinamika’s Director General Maxim Kuzyuk. “Finally, the new plant will significantly improve the stability of mechanical properties of welds and reduce the quality inspection costs in the process of welding.”

The new equipment will enable the Technodinamika’s enterprise to assimilate advanced aircraft welding technology at a whole new level and thereby improve the quality, reliability and durability of manufactured parts, reduce labor hours through the ability to weld large-sized, hardened titanium workpieces.

Technodinamika’s foundry in Ufa to start casting shipments to external customers in 2017.

The Technodinamika Holding Company, part of the Rostec State Corporation, launched a pilot project to integrate its foundry capacity on the premises of the Ufa Aggregate Production Association (UAPO) in 2014. As a result, the project has increased foundry production at UAPO by 30%.

“The main objective of the project is to reduce costs and speed up mastering of new products,” says Technodinamika’s Director General Maxim Kuzyuk. “The investments in the project amounted to less than 30 million rubles, which is tens of times less compared to the similar projects of other players in the market, where the cost of establishing a foundry may exceed 450 million rubles.”

The aluminum casting process was successfully assimilated at a cold-setting sand preparing area. By the end of 2015, UAPO has mastered 80 products for Technodinamika’s needs. Now, the foundry is fulfilling an order worth more than 40 million rubles for Aviaagregat, while the total volume of orders within the holding will amount to about 70 million rubles in 2016. In 2017, Technodinamika’s Foundry Competence Center will enter the external market and be ready to make castings also for other enterprises on a commercial basis.

“Thanks to our in-house foundry, the workpiece machining time at Aviaagregat has been reduced by 4 hours, while the casting weight decreased by 20%,“ exemplifies Alexander Kosov, Technodinamika’s Deputy Director General in charge of production, technology and quality. “Savings in raw materials and materials for series production castings through the in-house foundry totaled 15 percent.”

Now Technodinamika has started developing the magnesium casting process. “This is one of the most sophisticated processes, which the holding has not been engaged in previously,” notes Kosov, adding that the process development is scheduled for completion in early March this year.