Annotation: The article describes the problems of manufacturing large-size nozzle blocks by classical for Ukrainian space industry method of high-temperature brazing. The Yuzhnoye SDO-selected way of solving this problem and the first strides on the way to organization of new production using innovative technologies of laser welding and surfacing are presented. The step-by-step sequence and procedure of research work to develop and test a new technology of cooled nozzle block manufacturing are described. Four phases are identified, out of which the first two phases have already been successfully performed. The laser welding and surfacing technology will allow avoiding the use of costly and unique equipment and will allow reducing and optimizing the technological manufacturing cycle rejecting the long –term and energy-consuming technological operations. The scientific-and-technological works performed showed the principle feasibility of making connection between the external jacket and internal wall of a nozzle block using laser welding. The test samples manufactured confirmed the high strength characteristics, which had been preliminary obtained by the theoretical calculation methods. The sections obtained by surfacing demonstrate good metallurgical connection between the layers. On the test samples, the technique was tried-out allowing repairing defect areas in a welded seam obtained by laser welding method. This is especially important from the technological and economic viewpoints, as the technology of high-temperature brazing applied currently does not allow making guaranteed repair of brazed joints.

Annotation: The article presents the experience of the first liquid rocket engine parts developing and manufacturing by means of additive technologies. Application of these technologies imposes new constraints on parts configuration, which are necessary to be considered by a designer. At the same time, application of additive technologies provides new opportunities to a developer, which are absent at traditional method of manufacturing. The article presents the results of manufacturing in Yuzhnoye SDO the first commodity parts, manufactured by additive technologies – selective laser melting, using SLM280HL 3D- printer with building volume dimensions of 280x280x350 mm. The obtained experience in the first liquid rocket engine parts developing and manufacturing by means of additive technologies has shown, that application of this technology allows manufacturing the parts having high characteristics at minimum terms and cost of preproduction, however for all potential opportunities realization, especially at implementation phase, it is necessary to change designing philosophy, which will require more working hours at designing. The obtained first results conclusively prove efficiency and expediency of additive technologies application at certain segment of liquid rocket engine parts manufacturing, at that it is clear, that manufacturing equipment improvement and design methods evolution will lead to steady expansion of this segment.

Annotation: The process of introducing new technologies at Yuzhnoye SDO requires major changes of aerospace products designing methods and project management methods, which allows realizing new opportunities, reducing manufacturing expenses with simultaneous increase of products quality. New software products are presented directed at solving the problems identified when using additive technologies at Yuzhnoye SDO. Such as Autodesk Netfabb, AM Process Simulation, ESI Additive Manufacturing and others that allow optimizing the model for additive technologies through the change of material structure, taking into account and compensation of heat setting during printing propose the tools for creating bionic design. Creation of new technologies of producing cooled nozzle block of LRE chamber without soldering became possible due to integrated approach, with optimal combination of already existing technical solutions with principally new ones, such as laser welding and surfacing. The cost analysis is considered as the most effective optimization method at selection of optimal design and manufacturing technology for its possible implementation at the company. The personnel problem, the issues of quality improvement and labor productivity increase in all production phases are foundational to reduce manufacturing cost.

Annotation: This article considers the practical data on parts (specimens) manufacturing from powder metal material 316L using the innovative method of selective laser melting; the comparative study of the structure and physical and mechanical properties of 316L material, the combined influence of heat treatment and specimen orientation relative to the arrangement plate on the physical and mechanical properties and structure of specimens made of 316L alloy. Results are presented of the following: comparative study of the physical and mechanical properties and structure of specimens, manufactured using the selective laser melting technologies with horizontal and vertical placement relative to the arrangement plate; dependence of the ultimate strength and unit elongation on the annealing temperature. The possibility and suitability of the selective laser melting technology to manufacture parts and space-rocket hardware are evaluated. Experimental study of the specimens heat treatment conditions after selective laser melting enabled the definition of the optimal condition for the 316L alloy and have shown that heat treatment of the manufactured specimens under the heating at 1230 °С with the subsequent tempering at the temperature of 510 °С gives the homogeneous structure to the material of specimens made of alloy 316L, its dendritic structure, inherent in the specimen material in its initial condition, disappears after selective laser melting. Results of the mechanical tests of the obtained specimens have shown that the technology of selective laser melting provides development of products made of powder metal material 316L with optimal complex of physical and mechanical properties. It is shown that transition to the selective laser melting technology will enable production of the aerospace products, in particular geometrically-complex parts made of powder metal material 316L, in one technological cycle, excluding cutting, punching, refinement, cropping, welding, manufacturing of special tools or stamps