Site news 29.03.2017
Moscow, March 29, 2017
United Engine Corporation (a Rostec State Corporation company) intends to apply additive technologies in the production of Russian advanced gas turbine engines which will be certified in 2025-2030.
At the present time, the holding company is exploring the possibility to use additive technologies in engine-building.
"Additive technologies allow us to create highly effective products, - says Yuri Shmotin
, UEC Deputy General Director - General Designer. -With the use of additive technologies the manufacturing cost of production parts can be twice lower and the production time can be three times shorter than in the traditional approach. Additive technologies enable the use of brand new design methods and thus they allow the application of fewer parts in such complicated mechanical systems as gas turbine engines (GTE), gears, helicopters. Therefore, the new gas turbine engines we are developing today and are planning to certify in 2025-2030 are to be certainly manufactured by means of additive technologies. We expect parts produced using additive technologies to be up to 20% of the engine composition. This trend is a subject of interest for UEC and it is supported by the Government of the Russian Federation. We consider it necessary to join our efforts with other Russian enterprises”.
A meeting dedicated to the creation of Rostec’s single Additive Technologies Center (ATC) was earlier held on the premises of Rybinsk NPO Saturn PJSC (a United Engine Corporation company). Representatives of some leading holding companies and companies of the Russian aviation industry supported the idea of joint development of additive technologies and agreed on the format and principles of work organization in this field. Representatives of Rostec Corporation, UECC, Russian Helicopters JSC, Radio-Electronic Technologies Concern JSC, UAC PJSC, Roscosmos State Corporation, Technodinamika JSC and Russian-Singapore Business Council took part in the meeting chaired by Yuri Shmotin.
According to Valery Teplov, UEC Production Director, the formation of a working group is already under consideration in order to implement the Rostec ATC project.
"We have already addressed the question of forming a working group," - says Valery Teplov
. - Actually it is the starting point followed by the initiation of real actions, i.e. the transfer from discussions to the issue of administrative documents and then to the implementation "in hardware". We can say that the activities aimed at the establishment of the Rostec Additive Technologies Center have been launched”.
The participants of the meeting had a chance to see production and technical capabilities of NPO Saturn PJSC as concerns the development of advanced technologies including additive ones – the HIP area in shop #49, the foundry of shop #41, machining of parts in shop #34, SaM146 engine assembly in shop #80, and the Additive Technologies Center set up earlier and having no comparable counterparts in Russia. The delegations pointed out the high competencies of UEC’s Rybinsk Company in this field.
All the promising additive technology trends most demanded by industry are available at NPO Saturn's Additive Technologies Center. The Center focuses on the manufacture of gas turbine engine parts, modules, and units for aircraft and ground applications by means of layer-by-layer synthesis methods. Associated technologies are also presented there: heat treatment, laser welding and punching, an all-powerful metallurgical laboratory, computer-assisted tomography, electron microscopy, a non-contact optic digitization laboratory and engineering reverse. Key scientific-and-technical and technological tasks solved by the ATC: increasing the stability of GTE gas turbine engine element characteristics; the possibility to obtain a design with unique topology; reduction in the cycle and manufacturing cost of GTE parts; the use of materials the forming of which with the use of traditional technologies is either impossible or extremely costly.
NPO Saturn PJSC has developed and tested the part manufacturing chain using selective fusion starting from the development of a 3D model and finishing with a functional part. The innovative principles of design are implemented taking into consideration new technological capabilities including intellectual optimization of part topology ensuring the required strength with due account for the directions of acting loads and a significant weight reduction - the so-called bionical design. The Center is fully engaged in the activities aimed at having Russian metal powder compositions - first of all, these are the activities carried out by VIAM. In 2015 and 2016 more than 300 different development parts made of cobalt, titanium alloys, stainless steel by means of selective fusion passed bench tests in engine conditions successfully.
"The upgrading of any production is impossible without the application of new materials, innovative development and resource saving, - says Evgeny Kablov
, VIAM's General Director, Member of the Russian Academy of Sciences. - That's exactly why it is so important today to use advanced additive technologies which allow the creation of high grade parts with the least costs. Owing to additive technologies, it is possible to solve the main tasks facing modern engine-building industry."
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 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 industry’s companies by introducing new technologies meeting the world-class standards.
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. The Corporation comprises 700 companies, which form 11 defense-industrial and 3 civil industry holdings as well as about 80 direct control companies. The Rostec portfolio spans such renowned brands as AVTOVAZ, KAMAZ, Kalashnikov Concern, Russian Helicopters, VSMPO-AVISMA, and others. Rostec’s subsidiaries are located in 60 regions of Russia and deliver their products to over 70 countries worldwide. Rostec' s consolidated revenue reached 1 trillion 140 billion rubles in 2015. The average salary of the Corporation in 2015 amounted to 41 000 rubles, the tax payments to the budgets of all levels exceeded 160 billion rubles. Following Rostec's new strategy, the major objective of the Corporation is to ensure the technological advantage of Russia at the competitive world markets. The estimated investment for development till 2025 amounts to 4.3 billion rubles.