Assurance of parts accuracy in the process of coating deposition by the vacuum arc plasma

The deposition of vacuum ion-plasma coatings on high-precision parts of fifth generation aircraft hardware is a complex problem. Such parts have a complex thin-walled surface geometry with high accuracy in size requirements (5-6 accuracy degree), spacing and form accuracy requirements (4-6 accuracy grade). The model of the coating deposition by the vacuum arc plasma was developed. The model takes into account intraprocess repositioning of workpiece surface relative to the plasma flow. Adequacy of the model was confirmed by experimental data. On basis of this model the routine for the calculation of the coating thickness, spacing and form deviations of parts was developed. An analysis of different part locations in the adjustment device of processing setup can be made using the routine. Helicopter's thimble type parts ovality for different part locations and processing conditions was estimated with the routine. The process of coating deposition by the vacuum arc plasma on helicopter's thimble type parts was developed according to the estimation results. The reproduction run of such parts was processed. Developed model and routine can be used at the stage of vacuum arc plasma coating deposition process engineering.