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 СNС 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°С and cooling rate up to 300°С/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.