Engineering process


tech17

All the latest engineering solutions are aimed at improving the quality, service life, reliability of manufactured parts and engines on the whole. IVCHENKO-PROGRESS SE is involved in activities for the modernization of existing production processes and the development of own technologies on the basis of latest achievements in science and technology.

Metalworking
IVCHENKO-PROGRESS SE has facilities that are sufficient to manufacture the test batches of newly developed aircraft engines and ground application products at the state-of-the art level.

The factory is sufficiently equipped with modern metalworking equipment for manufacturing special gas turbine parts. The equipment changes all the time to support the introduction and use of advanced machining processes.

  • Integrated creep-feed grinding process on the 6-axis profile grinding machine for machining the sectors of nozzle guide vanes and rotor blades;
  • Integrated speed-milling process on the machining centers for compressor rotor blades and blisks;
  • Manufacturing process for advanced brush seals;
  • Ultrasound-assisted surface strengthening of parts;
  • Laser-assisted processes: sheet material cutting out;
  • Making perforations in different parts of gas turbines;
  • Punching the holes for vanes in the guide vane rings;
  • Processing the industrial rubber and composite materials;
  • Laser marking

Assembling
It is used the process of the optimized assembly of rotors involving ingenious mathematical algorithms and the most up-to-date computer equipment.

Toolmaking
Manufacture of dies, moulds, cutting tools, and gauges. There is also a carbide mills centralized manufacturing and resharpening unit equipped with imported or domestically produced equipment, with the possibility of manufacturing broaches, gear cutters, hobs.

The process of optimized assembly of rotors developed together with Kiev Polytechnic Institute was introduced. Application of uncommon mathematical algorithms and latest computer equipment enabled to minimize runout and imbalance of rotors.

One of the key activities directed to maintaining the engines in operation, is a continuous improvement of reliability and service life measures, consumer properties by introducing proven measures at different type of repair in accordance with established certification regulations.

This task was and still is one of high-priorities for the developer, and is solved by Ivchenko-Progress SE’s team successfully.

The process of optimized assembly of rotors developed together with Kiev Polytechnic Institute was introduced. Application of uncommon mathematical algorithms and latest computer equipment enabled to minimize runout and imbalance of rotors.

It is developed the manufacturing process of advanced brush seals which reduce leakages up to 80% as compared with conventional labyrinth seals, and have lower weight and dimensions.

Ultrasonic-assisted surface strengthening of parts used for improving their fatigue strength limit by 30% found its further development.

Use of laser process is expanded on cutting out and punching thin-walled parts, marking of parts made of different materials.

The high-speed directional solidification method of casting the blades was introduced, which allows to obtaine 170mm long blades free of surface defects.

The existing high-temperature steel grades and alloys feature higher physical and mechanical characteristics and a low cutting machinability, thus, cutting efficiency increase is actual. Implementation of high-speed cutting and creep feed processes ensures a 3 to 5 times improvement in efficiency.

Such blades have a few times reduced volumetric portion of microporosity and service life increased from 2 to 6 times.

To ensure a durable and reliable operation of blades their airfoil surface is provided with heat-resistant coatings applied by gas-circulating, plasma-, ion-plasma-spraying, or various other high-effective methods.

A specific attention is focused on restoration and repair processes. A unique process of restoration of the shroud damaged end faces by using the method of plasma-powder welding with a heat-resistant alloy that was implemented together with the Ye.O. Paton Electric Welding Institute and applied to a repair of blades featuring directional and single-crystal structures. It allows to restore a geometry of blade
with similar physical and chemical properties, operate the engine on condition for not shorter than 6,000 hours.

In cooperation with the National Academy of Sciences of Ukraine to expedite the repair and reduce labor expenditures it was Implemented an uncommon process of brazing and welding of cobalt-based wear-resistant plates onto the contact end faces of shrouds by using the argon-arc welding method. This allowed to avoid an expensive method of the conventional vacuum-brazing.

Polymeric composites such as carbon fiber-, glass fiber-, organic fiber plastics are widely used on the D-18Т, D-36, D-436Т1/ТP/148, АI-322/F, АI-222-25 engines and their modifications for reinforcing metal casings, manufacturing fan stator blades, noise suppressing panels, thrust reverser cascades, large-size air intakes, and, thus, supporting a durable and reliable operation of parts.


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