Site news 24.03.2015
March 24, 2015, Rybinsk. - The practical experience of using additive manufacturing in the creation of gas turbine engines was presented by NPO Saturn (a UEC company of the Rostec State Corporation) in the frame of the same-named section of the International technological forum “Innovation. Technology. Production” held on 23-25 March in Rybinsk.
According to NPO Saturn general designer Yuriy Shmotin, “NPO Saturn’s research and technology council has identified some key directions of development of the critical technologies ensuring a competitive edge for the company’s products in the future. One of such priorities is the development of additive manufacturing.
The ability to produce parts through additive manufacturing is becoming the foundation for the development of the newest materials and technologies to be used in the next-generation engines of both military and commercial aviation application, which cannot be produced in a conventional way.”
One year ago, on the territory of the NPO Saturn prototype plant’s newly built, state-of-the-art research and production facility, one of Russia’s biggest additive manufacturing centers was created. In April 2014, the commissioning of the one-of-a-kind equipment required for growing parts was conducted. The company has already been able to obtain some practical results. For instance, parts which have been additive-manufactured for the GTE-110 high-power gas turbine engine are now undergoing tests showing quite reassuring results.
The process of growing parts does not generate any pollution into the atmosphere, and is therefore considered a “green technology”. Thanks to the layer-by-layer production of parts, the company has secured an opportunity to drastically reduce the time of developing new products. Application of additive manufacturing allows to produce complex and unique parts with the minimal use of expensive tooling and machining, which means decreasing production costs.
For instance, according to Maxim Fedorov, chief engineer of the NPO Saturn prototype plant, “to produce a pre-mixing swirler for the same engine but using a traditional casting process, you would need two casting moulds requiring months for production and post-development. Whereas using such cutting-edge technology as additive manufacturing, we can grow this part in a matter of hours.”
According to the opinions of the participants of the “Additive manufacturing” section, the International technological forum “Innovation. Technology. Production” is a perfect venue for the professionals from different countries to discuss the most topical issues.
The NPO Saturn Research and Production Association (OJSC) is an engine-manufacturing company specialized in the design and development, production and after-market support of gas turbine engines for military and commercial aviation, naval ships and power-generating plants and gas-pumping units. The association is part of the Union of Russian mechanical engineers, an all-Russian public organization whereby the regional branch is headed by I. N. Fedorov, NPO Saturn CEO.
NPO Saturn is part of United Engine Corporation (JSC) and acts as the leader of the Commercial Engines Division, a business unit of UEC founded on 09.10.2012 as a result of integration of the following companies: NPO Saturn (OJSC), Aviadvigatel (OJSC), PMZ (OJSC), Metallist-PM (CJSC), Energetik-PM (OJSC), REMOS-PM (CJSC), Motoservis-PM (CJSC) and Zheleznodorozhnik-PM (CJSC).
United Engine Corporation (JSC) (a Rostec State Corporation company) is an integrated organization specialized in the design and development, serial production and after-market support of the engines for military and commercial aviation, space programs, the Navy, as well as for the oil and gas industry and power generation. One of UEC’s prioritized fields of activity is the implementation of comprehensive programs of development of the companies in the industry by introducing new technologies meeting the world-class standards. In 2013 revenues of the corporation amounted to RUB 158.9 billion.
The Rostec State Corporation is a Russian corporation established in 2007 in order to facilitate the development, manufacturing and export of high-technology industrial products of military and commercial application. Today it comprises over 700 companies, which form 9 defense-industrial and 5 civil industry holdings as well as 22 direct control companies. The Rostec portfolio includes such renowned brands as AVTOVAZ, KAMAZ, Russian Helicopters, VSMPO-AVISMA, etc. Rostec’s subsidiaries are located in 60 regions of Russia and deliver their products to over 70 countries worldwide. In 2013 revenues of the corporation amounted to RUB 1.04 trillion. Total taxation exceeded RUB 138 billion.
Chief engineer of the NPO Saturn prototype plant Maxim Fedorov holding an additive-manufacturing grown part 1 Mb