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Company Production base

The technological re-equipment program undertaken by NPO Saturn is implemented through purchasing of up-to-date multifunctional equipment and connecting it to the integrated information network, establishing specialized production lines and areas.

This enables carrying out various types of gas-turbine engine parts processing to a high degree of accuracy and reproducibility in the shortest possible time to specified parameters.

NPO Saturn has at its disposal production facilities enabling manufacture of gas-turbine components of any complexity, dimensions and mechanical characteristics.

The metal-processing equipment stock amounts to over 12,000 units, including about 2000 units of metallurgical equipment.

Automated production lines and N machines amount to over 40% of the total equipment quantity in some production directions.

The production basis includes casting, welding, machining, heat treatment, metal forming, and tooling.

Science-intensive technologies for manufacturing parts of composites, structural ceramics, and bimetals are widely used in pilot and series production.

Volume of investments in purchasing new equipment amounts to more than 3 bln. roubles.



Currently, at NPO Saturn within the scope of the through design-manufacture program on the basis of the integrated information system the following has been implemented:
  • Simultaneous product design, development of processes and manufacture of tooling on the basis of 3D models;
  • Integrated electronic database of manufacturing processes and documentation;
  • QuickCast build style pattern (stereolythography) of the most complex parts;
  • Industrial network of data transmission to CNC machines;
  • Automated production planning system;
  • Automated production cost accounting system.
The most significant production techniques are:

CASTING TECHNIQUES
  • Automated refractory coating application line;
  • Casting of blades by directed solidification method;
  • Single crystal blade casting.
WELDING, BRAZING, GAS-THERMAL COATING APPLICATION TECHNIQUES
  • Electron-beam welding of parts up to 3200 mm in diameter;
  • Gas-shielded welding;
  • Argon-shielded welding of complex-shaped parts in the chamber;
  • High-temperature vacuum brazing;
  • Gas-thermal deposition of sealing and wear-resistance coatings.
MACHINING
  • 5- and 6-axis machining centers;
  • Deep grinding machines;
  • Machining centers for large-size parts processing (up to 4 m).
HEAT TREATMENT TECHNIQUES
  • Heat treatment of parts at a heating temperature up to 1350° and cooling rate up to 300°/min;
  • Heat treatment and welding-up of parts up to 1300 mm in diameter in vacuum and shielded gas atmosphere;
  • Vacuum-flame deposition;
  • Ion nitriding;
  • Thermal vacuum treatment of parts.
ELECTRICAL DISCHARGE MACHINING
  • Processing of perforations with a minimum diameter up to 0.3 mm;
  • Broaching of slots and pockets in parts from hard-to-process high-temperature alloys;
  • Wire cutting of various configuration parts and components.
PROTECTIVE COATING APPLICATION TECHNIQUES
  • Gas-circulating aluminizing
  • Gas-circulating chrome aluminizing
  • Gas-circulating cobalt aluminizing
Volume of investments in purchasing of new equipment for the last 5 years amounted to more than 3 bln. roubles.



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