AP23487120 – Development of technology for manufacturing cylindrical parts used for military purposes

Objective of the project – to develop technology for manufacturing shell casings and parts of artillery shells by combining additive and cutting technologies.

Relevance: The relevance of the project is determined by the continuing high importance of artillery weapons in modern military conflicts. The experience of recent wars, including the conflict in Ukraine, demonstrates the massive use of artillery and a sharp increase in ammunition consumption, reaching tens of thousands of shells per day. This leads to a significant rise in costs and shortages of ammunition even in large countries. Given Kazakhstan’s dependence on imported artillery ammunition, particularly from Russia, there is a risk of shortages due to the current geopolitical situation. The absence of domestic production of combat shells increases the country’s vulnerability in terms of defense capability. Therefore, the development of domestic technologies for the production of artillery shells and their components is a strategically important and relevant task.

Scientific supervisor: Ph.D., Associate Professor, Mustafa Azamat

Expected and achieved results: During the implementation of the project, a comprehensive analysis of types of artillery shells and the materials used was carried out, which made it possible to identify the most demanded calibers in the army of Kazakhstan. A review of shell designs and their individual components was conducted based on open and restricted sources. Cooperation was established with enterprises producing training shells, and technologically complex components were analyzed. Based on the conducted studies, priority types of shells and their components were selected for development within the project. An analysis of materials used in shell production and their processing technologies was also performed. A database of microstructures of artillery shell materials was created based on the analysis of samples obtained from fragments of used ammunition and training shells. The microstructures of various materials were classified and systematized into a unified database. Standard welding wires with properties similar to shell body materials were identified. A Leica DMI8 metallographic microscope was acquired to enable detailed structural analysis of materials. Experiments were conducted to produce metal samples using arc welding adapted to additive manufacturing technologies with different types of wires. Technological parameters of the process, including current, voltage, and feed rate, were optimized to ensure stable layer formation. Microstructural studies revealed the formation of various phase structures depending on material composition. Additional studies using laser welding confirmed the possibility of obtaining high-quality metal layers with improved adhesion and structure, demonstrating the potential of additive technologies for manufacturing components of artillery shells.