BR24992870 "Ensuring sustainable development of Kazakhstan's machine-building industry on the basis of development, scientific validation, and implementation of industrial surface engineering technologies"

2024-2026 36 month SDG #9

SDG #9

Project Leader

Satbayeva Zarina, PhD

Relevance

Ensuring sustainable development of the mechanical engineering industry of Kazakhstan requires the introduction of modern technologies, including engineering approaches to improving the surface properties of parts. Surface engineering can significantly increase wear resistance, corrosion resistance and durability of parts, which is a key factor for the competitiveness of products in the domestic and global markets. The use of advanced methods, such as plasma and powder processing technologies, helps reduce the cost of materials, energy resources and equipment operation. These solutions not only stimulate innovation in mechanical engineering, but also reduce the environmental impact, strengthening Kazakhstan's position as a technologically advanced and environmentally oriented country.

Goal

Ensuring sustainable development of the Kazakhstan's machine-building industry on the basis of development, scientific substantiation and implementation of industrial technologies of surface engineering.

Expected Result

The following outcomes should result from the program:

1. Development of progressive plasma technologies of surface treatment of steels and alloys:
1.1 air-plasma method of obtaining heat-protective coatings on the basis of Zr-Y-O for heat-loaded elements of rocket-space equipment is developed;
1.2 reactive-plasma technology of spraying wear-resistant nitride coatings is developed;
1.3 an electrochemical method of cleaning the internal surfaces of the artillery gun barrel from fouling has been developed;
1.4 regularities and physical mechanisms of hardening of low-alloy steels at electrolyte-plasma surface hardening are investigated;
1.5 technological regimes and methods of chemical-thermal treatment of threaded pair “ Bolt and nut” are developed, allowing to increase its wear resistance and strength;
1.6 technological regimes of electrolyte-plasma nitrocementation of structural steels allowing to increase their mechanical and tribological characteristics are developed;
1.7 the method of micro-arc oxidation of aluminum alloy parts for increasing their tribological properties is developed;
1.8 technological regimes of ion-plasma nitriding have been developed, allowing to increase operational life and reliability of parts of shut-off and regulating valves;
1.9 ion-plasma technologies of formation of wear-resistant and superhard nanocomposite coatings on substrates from high-speed steels have been developed;
1.10 the scientific laboratory “Plasma technologies of suface treatment of materials” is created.
2. Development of innovative technologies for obtaining powder coatings with high mechanical, corrosion and tribological characteristics:
2.1 technology of high-velocity oxygen-fuel spraying of metal-ceramic coatings for hardening and restoration of military equipment parts has been developed;
2.2 technological regimes of Cr3C2-NiCr coatings deposition by the method of high-velocity oxygen-fuel spraying providing high corrosion resistance of boiler tubes are developed;
2.3 the technology of obtaining wear-resistant and high-strength electrical insulating coatings for application in friction units of thermonuclear reactors is developed;
2.4 the method of obtaining nanocomposite anticorrosion coatings for steel parts by cold gas-dynamic spraying is developed;
2.5 scientific bases for obtaining gradient detonation coatings with high adhesion strength and wear resistance have been developed;
2.6 scientific laboratory “Powder protective and hardening coatings” is created.
3. Development of technologies of hardening and restoration of worn-out machine parts:
3.1 technologies of hardening and restoration of parts by plastic deformation are improved;
3.2 experimental works aimed at increasing the efficiency of repair of parts of shut-off valves by means of plasma cladding are carried out;
3.3 experimental works aimed at increasing the efficiency of crankshaft repair by arc metallization have been carried out;
3.4 the method of electron-beam cladding for restoration of wear parts of crushing and milling equipment is developed;
3.5 the resource-saving method of hardening and restoration of transport-technological machines and complexes parts by arc metallization is developed;
3.6 stand and field tests of hardened and restored parts of machines and mechanisms are carried out;
3.7 a business plan for implementation of the developed technologies of surface treatment of steels and alloys is developed;
3.8 an engineering center for hardening and restoration of machine parts was established, which will provide engineering services to increase productivity and technical and economic efficiency of machine-building enterprises: pre-project works, development of technical documentation, production and complete delivery of equipment, optimization of operation processes, service maintenance and training of highly qualified personnel.
Final result:The program will result in the publication of:
1) at least 9 (nine) articles and (or) reviews in peer-reviewed scientific publications in the scientific direction of the program, included in the 1st (first), 2nd (second) and (or) 3rd (third) quartile by impact factor in the Web of Science database and (or) having CiteScore percentile in the Scopus database not less than 50 (fifty).
2) at least 10 (ten) articles in the journals recommended by Committee for Quality Assurance in the Field of Science and Higher Education of the Ministry of Science and Higher Education
3) at least 1 (one) monograph or training manual in foreign and (or) Kazakhstani publishing houses recommended by the Scientific Council and (or) Scientific and Technical Council of the applicant's organization;
4) at least 2 (two) patents in foreign patent offices (European, American, Japanese) or at least 2 (two) foreign or international patents included in Derwent Innovations Index database (Web of Science, Clarivate Analytics) or at least 5 (five) objects of ntellectual property (patent; for applications in the field of information technologies - copyright certificate) registered in the National Institute of Intellectual Property of the Republic of Kazakhstan. According to the results of the program an engineering center for strengthening and restoration of machine building parts will be created.

Achieved Result

The technology of high-speed oxygen-fuel spraying of WC-Co metal-ceramic coatings for hardening and restoring military equipment parts has been developed. A series of sprayings was carried out under various technological conditions, as a result of which the optimal spraying distance was determined – 350 mm, which ensures the formation of the most dense and homogeneous lamellar structure with minimal porosity (≈1.2%) and high adhesion.

A method of applying CR₃c₂–NiCr coatings by high-speed oxygen-fuel spraying (HVOF) has been developed, providing increased corrosion and wear resistance of boiler pipes made of 12X1MF steel. Work has been carried out to optimize the composition, structure of the powder and spraying modes in order to increase hardness and adhesive strength.

A technology has been developed for the production of wear-resistant and high-strength electrical insulation coatings for use in friction units of thermonuclear reactors. It was found that the optimal spraying distance of 150 mm ensures the formation of a dense, homogeneous structure with low porosity (~2.99%) and high microhardness (~1358 Hv₀.₁) and improved electrical insulation characteristics (er = 7.1–7.3; Rhigh ≈ 1.4 kΩ). As the distance increases to 200 mm, porosity increases (up to ~5%) and hardness and electrical resistance decrease by almost half.

A method for obtaining nanocomposite anticorrosive coatings for steel parts by cold gas dynamic spraying (CGDN) has been developed. It has been shown that agglomerated Al–Zn–TIO₂ powders provide the formation of dense, homogeneous coatings with high adhesion and minimal porosity (~0.95%), superior in quality to coatings made from mechanically mixed feedstock. The optimal process parameters (0.6 MPa, 600 °C, 15 mm, 90°) ensured a stable phase composition (Al, Zn, tio₂) without intermetallides and solid-phase adhesion to the substrate. The resulting coatings have high corrosion resistance (reducing Icorr by an order of magnitude, shifting Ecorr to the noble side) and improved tribological properties — a coefficient of friction of 0.4–0.5 and a reduction in wear of up to 50% compared with untreated steel.

A scientific basis has been developed for the production of aluminum oxide-based gradient detonation coatings with increased adhesion, hardness, and wear resistance. It is established that the optimal distribution of the α- and γ-al₂o₃ phases over the layer thickness ensures a smooth transition of properties from a viscous sublayer to a high-strength surface. Gradient coatings are characterized by increased microhardness (up to 14-14.5 GPa), lower porosity, and a denser structure than homogeneous coatings.

The laboratory "Plasma technologies of surface treatment of materials" has been established on the basis of the "Sakarim University". The main activity of the laboratory "Powder protective and strengthening coatings" is aimed at the development, production and research of coatings formed by thermal spraying and surfacing methods (HVOF/HVAF, APS, PTA, electric arc metallization). The laboratory carries out work to improve the wear resistance, corrosion and thermal resistance of materials, as well as to restore and strengthen parts of mechanical engineering, aviation and energy equipment.

The engineering center "Hardening Technologies and Coatings" has been established on the basis of Shakarim University. The Engineering Center "Hardening Technologies and Coatings" is a modern research and educational platform of the university, where fundamental science and applied developments are combined.

Publications in journals recommended by the KOKSNVO.

1. Zhasulan A.Zh., Satbayeva Z.A., Ormanbekov K.D., Shynarbek A.B., Kusainov R.K. Assessment of the toxicity of nanocomposite coatings formed by microarc oxidation // Bulletin of Shakarim University. Technical sciences. – 2025. - №2(18). - Pp. 443-453. https://doi.org/10.53360/2788-7995-2025-2 (18)-55.

Published: June 27, 2025

2 Kadyrbolat N.Ye ., Satbayeva Z.A., Kurmangaliev R.Kh ., Kusainov R.K., Shynarbek A.B., Bakhyt Zh.A. Analysis of the Effects of Electrolytic Plasma Hardening on the Mechanical Characteristics of Steel 45 Employed in the Production of Harrow Teeth // Bulletin of the National Research Center of the Republic of Kazakhstan. - 2025. - No. 3. pp. 5-13. https://doi.org/10.52676/1729-7885-2025-3-5-13 .

Published: September, 2025

3. Kakimzhanov D.N., Satbayeva Z.A., Dautbekov M.K., Turabekov Y.S., Kuanyshbay R.M., Rustemov A.S. Influence of Spaying Parameters on the Property of Detonation Coatings Based on // Bulletin of the Karaganda University. The "Physics" series. – 2025. - №30. – 1(117). – Pp. 53-59. https://doi.org/10.31489/2025PH1/53-59 .

Published: March 21, 2025

4. Zhasulan A.Zh., Leonidova A.B., Turar Zh., Bakyt Zh.A. Stress effect on tribocorrosive properties of calcium phosphate coatings obtained by microarc oxidation // Bulletin of Shakarim University. Technical sciences. – No. 2(18) 2025. – pp. 377-384. https://doi.org/10.53360/2788-7995-2025-2 (18)-46.

Published: June 27, 2025

5. Rakhadilov B., Shynarbek A., Ormanbekov K., Zhassulan A., Kadyrbolat N., Musataeva N. Study of Corrosion Characteristics of 65G and 45 Steels before and after Electrolytic -plasma Hardening//Vestniknyats. -2025.-No. 2.-P.74. https://doi.org/10.52676/1729-7885-2025-2-74-81 .

Published: June, 2025

Publications in foreign peer-reviewed scientific journals.

1. Rakhadilov B., Satbayeva Z., Maulit A., Kurmangaliyev R., Rustemov A. Effect of Electrolytic-Plasma Hardening on the Microstructure and Tribological Properties of Low-AlloySteels // Metals. – 2025. - No. 15. – p. 698. https://doi.org/10.3390/met15070698 . (the percentile in Scopus is 61%, the quartile of the magazine is Web of Science – Q2)

Published: June 23, 2025

2. Satbayeva Z., Zhassulan A., Rakhadilov B., Shynarbek A., Ormanbekov K., Leonidova A. Effect of Micro-Arc Oxidation Voltage on the Surface Morphology and Properties of CeramicCoatings on 7075 Aluminum Alloy // Metals. - 2025. - No. 15. – P. 746. https://doi.org/10.3390/met15070746 . Publication date: 07/02/2025 (percentile in Scopus is 61%, quartile of the journal in Web of Science is Q2)

3. Rakhadilov B., Berikkhan K., Satbayeva Z., Zhassulan A., Shynarbek A., Ormanbekov K. Optimization of Cold Gas Dynamic Spray Coatings Using Agglomerated Al-Zn-TiO2 Powders on Steel // Metals. – 2025. – No. 15. – P. 1011. https://doi.org/10.3390/met15091011 . (the percentile in Scopus is 61%, the quartile of the journal in the Web of Science – Q2)

Published: September 11, 2025

4. Rakhadilov B., Kakimzhanov D., Mural A., Turabekov Y. Effect of Technological Parameters of Detonation Spraying on the Properties of Cr2O3 Coatings // Coatings. – 2025. - No. 15. – p. 943. https://doi.org/10.3390/coatings15080943 (the percentile in Scopus is 66%, the quartile of the journal in Web of Science is Q2)

Published: August 12, 2025

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