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Chemical and galvanic conversion plating
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Thermal spray coating
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Spacecraft testing
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Strength and leakage tests of tanks and units
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Contact flash welding
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Fluorescent control
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Vacuum induction melting technology
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Plasma spraying
Chemical and galvanic conversion plating

YUZHMASH has a full range of technologies and equipment for chemical and galvanic processing of parts and components of manufactured products.

To ensure corrosion resistance of parts made of structural steels and aluminum alloys, we carry out the following chemical and galvanic coatings: zinc, cadmium plating, oxidation, anodizing, chemical passivation. If necessary, additional corrosion resistance is increased by paint application.

Depending on the warranty period for product specialists determine the type of plating and application method.

To improve the wear resistance of steels, aluminum and titanium alloys are used chrome, chemical nickel plating and hard anodizing.

Chemical milling is used to obtain the size and weight characteristics of large parts of aluminum alloys, when the machining of parts cannot gain the necessary characteristics. We use the following methods: dipping into the solution components, jet method, or pouring the solution directly into the part.

Copper, silver, nickel, manganese plating is widely used as a solder for diffusion soldering. Silver, tin, tin-bismuth alloy plating is used for low-temperature soldering.

To protect the walls of the details of the burning at high temperatures we apply porous chromium or chromium nickel-chrome plating.

Tight of different joint is ensured by applying thick copper silver plating to the sealing gaskets.

The plating quality meets the requirements of international standards and specifications for the product.

The plating provides high operational reliability of manufactured products.
Thermal spray coating

Thermal spray coating (TSC) is a local melting (softening) of the material and its spraying by high speed compressed air or gas jet. After contact with a solid substrate droplets flatten, mix and create a coating (surface). 

Coating materials available for thermal spraying include wire, powder or powder-filled polymer.

The coating precursor is heated by:

 - welding arc (plasma spraying); 
 -electric arc is generated between two consumable metal wires (wire arc spraying); 
 -mixture of oxygen and fuel gases (detonation spraying); 

Thermal spraying can provide coatings of any composition over inner and outer surfaces of various parts. Coating materials available for thermal spraying include metals, alloys, ceramics, plastics and composites (thickness range is 20-30 micrometers). The thickness is limited by the economic feasibility of coating.


Significant advantages are: equipment usability, low cost, versatility, the possibility to organize the process of spraying in any conditions, as well as the possibility of obtaining different properties of coatings on various substrates.

The benefits of TS coating:

 - reduction of cost and repair time; 
 -application of cheaper materials or fewer due to the wear resistant, corrosion-resistant, heat-resistant, heat-conducting, conductive and insulating coatings; 
 -creation of structures that require special coatings: rocket and aircraft engines, components of nuclear reactors and MHD generators, aircraft landing gear made of titanium alloys, etc.; 
 -products weight reduction by applying light coatings instead of sleeves, facings, shirts, reduction of the temperature gradient, etc. (space objects, chemical and power equipment). 


This technique is mostly used in nuclear engineering, high temperature physics, metallurgy, mining, chemical and agricultural engineering, medical engineering, construction, transport engineering, electrical engineering and other industries that require coating heat-, erosion- and wear-resistant, corrosion resistant, electrically conductive and insulation, with high or low coefficient of friction, for the restoration of worn surfaces, sealing of cracks and other purposes.

The company uses this technology for spraying bronze, antifriction, ceramic, thermal erosion and anticorrosion coatings.

Application at YUZHMASH

Application of technology in the manufacture of parts of landing gear for AN aircraft:

 - anti-friction wear-resistant bronze coating on pistons, rods, axle-boxes, which reduces the number of parts, weight and simplifies structure; 
 -coatings of tungsten, cobalt, nickel, aluminum, using titanium alloys in landing gear design; 
 -zinc corrosion resistant coating that provides corrosion resistance of steel parts during life time. 

Thus, TSC make it possible to manufacture parts for AN landing gear, and any costs to develop and apply this technology are economically effective.

Since 1963 YUZHMASH is equipped with facilities for plasma spraying: UPU-3D, UPU-8M, and electric plating BM-2 complex. Spraying is carried out on specialized machines that allow applying coating on the outer and inner surfaces of parts of variable cross section.

Quality guarantee 

The quality of coatings performed at Yuzhmash meets all the requirements for products that are made for international programs and projects - "Cyclone" launch vehicle, "Vega" liquid rocket engine, landing gears for AN aircraft.

More than 40 years experience in coatings together with high qualification of engineers and technicians of YUZHMASH allows solving complex technical tasks.
Spacecraft testing

The only one in Ukraine testing camera for function of the spacecraft was put into operation at YUZHMASH. All the equipment of the chamber is made using nanotechnology.

Testing for function of the spacecraft are conducted in a temperature and vacuum test chamber, which recreates the effect of solar radiation, infrared radiation of the Earth and space vacuum. The camera imitates the effect of outer space. Complex of electrical and functional tests also is carried out.

Quality characteristics of specialized microsatellites and testing technology meet international standards.
Strength and leakage tests of tanks and units

In the main assembly workshop are made tests for strength and leakage of the fuel tanks of launch vehicles "Zenit", "Taurus-II", "Cyclone-4".

Strength tests are carried out with compressed air by using special pneumatic panels in armored boxes size of 30 × 11 m, strength characteristics of the box P.V = 2160000kgs/sm2 × l.

Strength of the fuel tanks is tested by hydraulic pressure on the hydraulic stand using corrosion-resistant solution in a vertical position.

The fuel tank containment is tested by the following methods:
 - accumulation of air-helium mixture using devices such as mobile leak detector for permissible leakage of 1 × 10-7m3 × Pa/s; 
 -vacuumization of air-helium mixture in a vacuum chamber with a diameter 6.3 m and length of 25m. Strength characteristic PV = n × 750000kgs/sm2 allowable leakage at 1 × 10-7m3 × Pa / s.

Purity requirements for fuel tanks internal cavities with installed structural elements meet special technology of blasting mechanical impurities for internal cavities of nodes (chips, metal dust and other foreign particles) by the corrosion solution hydraulic stand.
Contact flash welding

Contact flash welding (CFW) is a high-performance technological process in which the welded parts are pressed together by coupling edges.

Considering high requirements for the quality of welded joints, YUZHMASH uses the best welding materials of Russian and foreign manufacturers.

The company provides a contact flash welding of extruded sections, tube preforms of steel and aluminum materials.

The company renders service of contact flash welding of extruded sections, tube preforms of steel and aluminum materials.

YUZHMASH applies welding technology in semi-solid phase. This radically simplifies the process of welding of aluminum alloys type AMG-6, 01570.

CFW ensures high quality and reliability of welded joints. The process of welding is carried out in a short period of time, which saves electricity. The process runs in automatic mode, which ensures high stability of the welding process in accordance with the specified mode.

The advantages of CFW:

 - high performance; 
 -high quality of welded joints;
 -reliable connections; 
 -high technical and economic indicators of production. 

The unique welding equipment securely pressed together extruded sections with a diameter over 800 mm and a height of 400 mm

The technology is widely used in the production of heavily loaded units of launch vehicles.


Heavily loaded units of launch vehicles:

 - frame made of high-strength steels and aluminum alloys; 
 -shells of body made of AMG6 alloy, diameter of 1800 mm or more, cross-section up to 100,000 mm2 (50 x 200 mm); 
 -fitting + stringer of high-strength steels. 

The original solution implemented in the construction of launch vehicles units, which have fitting + stringer, formerly connected with riveting.

Replacement of riveted joints welded reduced the weight of the structure and provide high performance products.

Fluorescent control

On September 2009 YUZHMASH installed and now uses actively the fluorescent control GS-1206-4.4. This line is designed for the detection of surface discontinuities, defects by the method of capillary flaw detection (OST 190282-79 Lum 1-OV, nondestructive testing).

Ultra-high sensitivity (corresponding to the 1st conventional level of OST 190 282, GOST 18442, or the 4th level of foreign n standards) reveals a defect (crack) with a minimum value of opening - 0.5 microns. The limiting sensitivity can be achieved when the roughness grade no lower than fifth.

The line has a manual control system equipped with a circulating (monorail) suspension-type conveyor. Bracket for moving parts can withstand loads of up to 150 kg.

Availability of special UV spray equipment and a darkened inspection cabin allows using specifically contrasting fluorescent penetrates as consumables.

The fluorescent control line has two drying chamber, each of them is configured as a continuous air flow (t = 70-90 º C). The size of the drying chamber allows control of large details.

The OST 190282-79 Lum 1-OV line provides an opportunity for control the base metal and welded joints, nodes at different stages of manufacturing, in service, in the repair of items of aircraft, rocket and space technology, as well as in other industries. Capillary method allows testing objects of any shape, of different sizes, made of ferrous and nonferrous metals and alloys, plastics, glass, ceramics and other hard non-ferrous materials.

The complete check out of details takes about 2 hours.

Carbon filters ensure environmental purity of the line.

Upon test completion experts make a condition inspection report of the detail.

The company's employees passed specialized training to work on the line, and also have certificates of non-destructive control issued by the Notified Authority for certification of personnel in the field of non-destructive control. Personnel certification on luminescent control takes place every three years.
Vacuum induction melting technology

Vacuum induction melting furnaces are widely used in the company for 40 years.

Metal melts under vacuum conditions.

EP202, ZhS-ZDK and other rolled alloys including tungsten, cobalt, molybdenum and titanium are used for melting alloys.

This technology allows to produce castings up to 15 kg weight.

Castings of high-temperature alloys are used in rocket and space technology.
Plasma spraying

YUZHMASH one of the first successfully applied plasma spraying in the manufacture of elements of rockets and space technology.

The application of tungsten carbide coatings of nozzles on the first stage of launch vehicle increases their resistance to high temperature erosion of more than 100 times.

Plasma spraying improves wear resistance, impact of heat flow, erosion and corrosion of the surface of rocket engines.

Coating application increases the service life of components, and also allows restoring it over and over again.

Plasma-arc spraying technology can solve various problems of protection constructions and details from wear, corrosion and thermal effects in mechanical engineering, metallurgy, energy, aviation, space technology, electronics, medicine and other fields of human activity, as well as to create new and better types of equipment and devices.