ZAPOROZHYE MACHINE-BUILDING DESIGN BUREAU PROGRESS STATE
ENTERPRISE NAMED AFTER ACADEMICIAN A.G. IVCHENKO
Zaporozhye Machine-Building Design Bureau Progress State Enterprise named after Academician A.G. Ivchenko contributed much to the development of aviation industry. This is the Company, which for over 68 years has been involved in design of engines to power aircraft and helicopters of various types, and also drivers and special equipment of industrial application. For this period of time more than 80000 aviation piston and gas turbine engines, turbine starters and drivers of industrial application have been produced by engine manufacturers. The aero engines designed by SE Ivchenko-Progress power 54 types of A/C in 122 countries of the world. Total operating time of GTEs exceeds 300 million hours. The company is a part of the Ministry of Industrial Policy of Ukraine
HISTORY OF SE IVCHENKO-PROGRESS FOUNDATION
On May 5, 1945, under the People’s Commissar of Aviation Industry A. I. Shakhurin’s order No. 193 an Experimental Design Bureau (EDB) was established at EDB-478 plant to design new and update aero engines of medium and low powers designed earlier for civil aviation. A regular designer Alexander Georgiyevich Ivchenko was appointed to be a Chief of the EDB who later on (in 1963) became a Designer General of the Enterprise. The backbone of the new design bureau comprised the experienced specialists of the engine-manufacturing plant, which had passed a splendid school of design and development of aero engines ranged from М-11 to М-88B and Ash-82FN. In 1966 the enterprise was renamed to Progress Zaporozhye Machine-Building Design Bureau (ZMDB). Since 1994 the enterprise was named after Academician A.G. Ivchenko, and since 2004 – SE Ivchenko-Progress
Outstanding designers who headed Zaporozhye Machine-Building Design Bureau Progress named after Academician A.G. Ivchenko :
As far back as 1946 at the EDB created was an engine M-26GR (helicopter, geared) rated at 500 hp. It was the first air-cooled reciprocating engine in the world designed specifically for powering helicopters. The engine was given an index of “AI” (Alexander Ivchenko) – АI-26GR. The AI-26GR prototype engine and its updated versions: AI-26GRF and AI-26GRFL rated at 550 hp and 575 hp respectively, were powering the I.P. Bratukhin G-4, B-5, B-10, B-11 and A.S. Yakovlev Yak-100 helicopters. 30 prototype helicopters and 250 units of AI-26 GR/GRF engines were produced in total.
Majority of the first prototype and production helicopters in the USSR were powered by reciprocating engines designed by Zaporozhye EDB.
As beginning from 1947, the enterprise has proceeded with experimental works on creating a light engine, AI-10, an air-cooled 5-cylinder star rated at 80 hp, for powering the Yak-20 training and sporting aircraft. Only 2 prototype aircraft and 9 motors were produced.
In 1948 the AI-4G engine rated at 55 hp was developed for powering the ship-based Ka-10 observation and liaison helicopters. Manufactured were 15 heli-copters and a small lot of engines – 35 units.
In the same year developed was a unique engine AI-14. Its aircraft version, AI-14R, an air-cooled 9-cylinder star with supercharger and reduction gear rated at 265 hp, was powering the different versions of Yak-12 and Yak-18 airplanes. These airplanes were both of training and combat application. 12000 units of airplanes were serially produced in the USSR, Poland and China; of them nearly 8500 units were powered by the AI-14 engines. Over 12500 units of various versions of AI-14R were produced in these countries in total. Also this engine was powering the STOL An-14 Bee aircraft; 327 airplanes have been serially produced. And through present the engines of the AI-14 family, under the M-14 trademark, power thousands of A.S. Yakovlev and P.O. Sukhoy light trainers, aerobatics, executive and agricultural airplanes, and are operated in many countries of the world.
The helicopter version of this engine, AI-14V, rated at a range of 255 to 280 hp was used for powering the Kamov ship-based multipurpose Ka-15 and Ka-18 helicopters. Totally 465 helicopters and 1200 engines were manufactured.
Also in 1948, based on the AI-10 and AI-14 motors, created was an airplane seven-cylinder air-cooled radial engine, AI-12, rated at 175 hp. The engine has undergone flight tests as installed in the Yak-18M and Po-2 airplanes. A pilot batch of 4 engines was manufactured.
In these years the cooperation of our company was especially successful with the M.L. Mill’s Design Bureau. Within a short period of time the Mi-1 helicopter powered by the AI-26V engine rated at 575 hp was created and tested. The helicopter, designed in 1953, had more than ten modified versions both of civil and combat application. Its production was developed in two countries, the USSR and Poland, and totally 2691 units were manufactured. Manufactured were in total more than 4000 units of the AI-26V engine (under Lit-3 trademark in Poland).
Since 1953 the EDB has started the works on creating gas turbine engines. The first activity in this direction was the development of a powerful turbine starter, TS-12, for the NK-12 turboprop engine, that was being created at the state, of national standing, experimental plant No. 276 headed by N.D. Kuznetsov. These engines were powering the passenger Tu-114 and military An-22, Tu-95, Tu-126, Тu-142 aircraft. Totally 2500 units of TC-12F turbine starters were manufactured.
With the purpose to supply compressed air for starting the АI-14V and АI-26V main propulsion piston engines powering the Ка-15, Ка-18 and Мi-1 helicopters, in 1957 created was a starting piston engine, АI-2МК. Over 5000 units of the starting piston engine were produced.
With the purpose of obtaining an experience in developing and refining gas turbine engines, the N.D. Kuznetsov EDB has transferred its TV-2F engine and technical documentation to it to the Zaporozhye EDB. Based on this engine in 1954 the Zaporozhye EDB has developed a modified version, designated as TV-2T, rated at a maximum power of 6250 ehp for powering a prototype transport aircraft, An-8 (P). A pilot batch of 7 engines was manufactured.
In 1955 yet another modified version of this engine, TV-2VK, was developed at our company, rated at a maximum power of 5900 ehp, featuring an ingenious reduction gear for driving the lifting rotors and tractor propellers of the largest rotorcraft in the world, Ka-22, of N.I. Kamov’s design. World records on flight speed and altitude were established with this prototype rotorcraft. The engines were powering the first prototype of the Ka-22.
In 1957 a turbojet engine, AI-7, rated at a maximum thrust of 60 kgf was created for powering an experimental V-7 (Mi-7) helicopter. Two engines were installed at the ends of the two-bladed lifting rotor, and the rotor was spinning up under the action of their jet thrust. In 1959 the activities on creating the AI-7 engine were aborted due to the fact of closing the V-7 helicopter program. A single prototype helicopter and 11 engines were manufactured.
In the same year, 1957, a single-shaft turboprop engine, AI-20, one of the world’s first GTEs featuring long service life, had passed successfully the state tests. It is an engine of simple design, maintainable and inexpensive in production, featuring high operational reliability. For many years its modified versions: AI-20A (of four series), AI-20D (of five series), AI-20K, AI-20M rated at a range from 4000 to 5250 ehp were operated successfully as installed in the passenger airplanes An-10, Il-18, as well as in the AF’s airplanes An-8, Il-20, Il-22, and even today continue to power the An-12, Аn-32, Be-12 and Il-38 aircraft. With the AI-20M engine in the course of its operation, for the first time in the USSR a TBO of 8000 h and an assigned service life of 22000 h were achieved. In total manufactured were 2663 aircrafts and about 14000 units of AI-20 engines of all modified versions.
Starting from the 1960s the EDB have been involved in the activities on the development of bypass GTEs. In 1965 the AI-25 turbofan engine rated at 1500 kgf was designed to power Yak-40 aircraft, it was manufactured in a series of 1011 units. It was also operated as installed in M-15 agricultural airplane (Poland), 138 airplanes were produced, 6325 engines were in series production.
In 1958, based on the experience gained in the course of designing the AI-20 turboprop engine and on the advanced method of simulation, a turboprop engine, AI-24, rated at 2550 ehp was developed. The engine modified versions are powering the passenger An-24 aircraft and the Аn-26, Аn-30 special-purpose airplanes. 2735 aircraft and 11 750 units of the AI-24 engines of various modified versions were manufactured in total. In 1960 11 units of AI-24V turboshaft engines rated at 2000 hp were manufactured for powering the first two V-8 (Мi-8) prototype helicopters. Later on, due to the fact of selecting the TV2-117 engine for powering the Mi-8, the works on the AI-24V engine aborted.
In 1973 a modified version of the AI-25TL engine rated at a thrust of 1720 kgf was created for powering the L-39 trainer produced in Czech Republic. The engine was developed based on the AI-25 turbofan bypass engine featuring an extended exhaust pipe, HPT cooled blades and oil system providing operation of bearings under conditions of inverted flight. More than 5100 engines were serially produced. At present, about 2650 AI-25TL engines are operated 37 countries of the world powering both the training and combat aircrafts. Totally 2868 units of L-39 airplane were produced. The AI-25 engine modified version, AI-25TLK, powers the JL-8 trainer (China), there are nearly 300 engines in operation; another modified version, AI-25TL 300.11, is applied for powering UAVs.
The 1960s were marked by developing a family of small auxiliary power units (APU) for driving electrical power generators, for air-conditioning system operation, for supplying compressed air when starting the propulsion gas turbine engines both of civil and combat aviation. The family includes the AI-8, AI-9 and AI-9V APUs for the An-8, An-10, Be-12, M-15, Yak-40 airplanes and for majority of Kamov helicopters: Ka-27, -29, -31, -32, -50, -52, -60, and Mill helicopters: Mi-6, -8(17), -10, -14, -24(35), -26, -28. In total nearly 9900 aircraft equipped with APUs of these types and 13000 starter engines were produced. At the present time 7000 units of APUs are in operation.
In 1971 the first in the USSR high-bypass turbojet engine, D-36, featuring a maximum thrust of 6500 kgf for powering a new Yak-42 passenger aircraft was designed. For the first time a three-shaft configuration featuring wide application titanium alloys, and advanced design, engineering and metallurgical novelties were introduced into the engine of such a class. Also it was for the first time in domestic engine-manufacturing industry when an engine was executed according to the modular design. The next improved versions of this engine are successfully operated on combat transports and multipurpose airplanes An-72, An-74, as well as on the An-74TK-300 passenger aircraft. In total 350 aircrafts were manufactured and about 1700 engines were serially manufactured. At the present time about 720 units of the D-36 engine are in operation.
In the middle 1970s based on the D-36 engine a turboshaft engine, D-136, rated at 11400 hp was created for powering the Mi-26 combat transport helicopter featuring the highest cargo-lifting capacity in the world. Manufactured were 288 helicopters and 945 engines, and 400 units are currently in operation.
Within the frameworks of military-technical cooperation between the countries-members of the CMEA (Council for Mutual Economic Aid), a turbofan bypass engine, DV-2, was designed in 1984, featuring a maximal thrust of 2200 kgf for powering the L-59 trainer of Czech production. 65 aircraft have been produced. Starting from 1991 the engine was under production in small series of 70 units in SlovakRepublic.
In the first half of the 1980s the main efforts of the company were forwarded to the development of a turbofan engine of ultrahigh thrust for powering the An-124 Ruslan strategic military transport airplane. Created was a powerful high fuel-effective engine, D-18T, rated at a thrust of 23430 kgf. It was also installed on the An-225 Mriya airplane featuring the highest cargo-lifting capacity in the world. In total, 52 airplanes and 251 engines were manufactured. 188 units of the D-18T engine are currently in operation.
The first domestic and the first in the world three-shaft prototype demonstrator engine, D-236T, rated at a maximum power of 9450 ehp was created, and tested in 1985. The engine was developed with the purpose of solving the problems related with creation of engines based on the propeller-fan configuration. Manufactured were two specimens of this engine.
INDUSTRIAL SECTOR IN SE IVCHENKO-PROGRESS HISTORY
An individual line of the company’s activities is the development of drivers for
industrial application. SE Ivchenko Progress has gained a great experience in
developing drives for the national economy demands. The history of activities
in the industrial field runs back to the 1950s.
In the first place developed were the piston engines: the AI-2 for driving the noted throughout the world Druzhba power saw, manufactured were over 3 million units; AI-14PS for driving the Sever-2, Ka-30 snow-planes, and the Raduga air-cushion craft, nearly 450 units of this engine were produced. Also a whole family of racing engines, SICH, was created, for motor-boating sports application.
At the beginning of the 1960s the era of applying the gas turbine drives (GTDs) in the national economy originates. Based on the AI-20 and AI-24 aero engines families of drives were created that were being installed in the following prototype articles: “SM-6” ekranoplan (a prototype of the “Caspian Monster” vessel), “Burevestnik” and “Tayfun” hydrofoil ships, as well as the “Sormovich” hovercraft. Also the GTDs were being used for driving the AI-24PGTE and PAES-2500 mobile electrical power stations, the 2UVAG water heating unit, BTU-800 mobile gas turbine-pumping unit, power station of Sever-1 pipe-welding facility, and as a source of compressed air for TKADS-200M oxygen-nitrogen-producing station.
The AI-8 auxiliary power unit has found its application in starting the main gas turbine drivers of Kalmar, Omar, Kasatka, Murena hovercrafts, and hydrofoil carrier platform of the VNT-1 helicopter non-contacting gangway. And, in our days, many production vessels are still in operation.
In the early 1970s, by the order of the Ministry of Coal Industry of the USSR, based of the AI-8 APU developed was an inert gas generator, GIG-4, featuring high capacity and self-containment, which allowed to reduce the time of suppressing underground fires and to prevent methane explosions. This unit is widely used in many domestic coalmines to perform rescue operations, and also in Poland and CzechRepublic, where it is operated up to now.
Particularly shall be noted the works fulfilled at the request of the Ministry of Oil and Gas Industry. Drivers operating by using both diesel fuel and natural gas were created for a family of Uralmach drilling units; as well drivers intended to intensify the oil production were created. 670 drivers were serially produced. Many of oil and gas fields in Siberia were developed by using these drivers.
Based on the AI-25TL engine, gas turbine drivers for the PEM-1 search-and-rescue road-free vehicle and UTM, TMS-65M military equipment thermal treatment machines have been developed.
SE IVCHENKO-PROGRESS today
The sphere of SE IVCHENKO-PROGRESS activities covers design, manufacture, test, development, certification, putting into series production and overhaul of gas turbine engines both of aviation and industrial application. More than 60 certificates of Bureau Veritas, EASA, Central Civil Aviation Administration of China, IAC AR and GosAviaSluzhba of Ukraine confirm a type design conformity, quality, reliability and the right to design, manufacture, overhaul and upgrade the engines.
To meet the expected growth in demand for aeronautical products the company is involved in the development of a number of new aero engines of civil and military application. Especially, it is the first in the world turbopropfan engine, D-27, rated at a maximum power of 14000 ehp, which is currently under official flight testing as installed in medium-range military airlifter An 70. The extensive preparation works to put aircraft and engines into series production have been fulfilled now, as well as, the development of a modified version, designated as AI-127, with a power of 14500 hp, a family of ultra bypass turbojet engines (about 13), AI-727, with a thrust of 9000…11000 kgf, driven by a reduction gear of noiseless wide-span fan of new generation designed for An-148T-type transport airplanes.
ТV3-117VМА-SBМ1 turboprop engines and АI9-3B auxiliary power unit have been developed for a new regional An-140 aircraft. The works on a further extension of service life and improvement of reliability are performed with these engines.The new passenger aircraft, Tu-334, An-148, as well as, Be-200 amphibian are ascended to the sky by new-generation engines of the D-436 family rated at a thrust ranged from 6400 to 8200 kgf. The engine series production is executed in cooperation of Motor Sich, JSC (Ukraine) with FGUP Salut MMPP and UMPO JSC (Russian Federation). In November 2008 the D-436TP turbofan engine, the first in the post soviet countries, received an airworthiness approval from EASA on compliance with the western airworthiness standards, while ensuring to Be-200ChS amphibian entering the European market.
Now, a family of AI-222 turbofan engines with a thrust ranging from 2200 to 4500 kgf (afterburning version) designed for powering modern combat training airplanes is under development. In 2009 the program was completed and the Report on the joint state flight tests of Russian Yak-130 combat trainer powered by AI-222-25 engines rated at 2500 kgf was signed.
The AI-222-25 series production is executed in cooperation with Motor Sich, JSC and FSUE Salut MMPP. The development of the AI-222-25F rated at 4200 kgf with afterburning power is at a final phase. The works on the development of AI-222-40 turbofan engine with a thrust of 3500-4150 kgf based on the baseline engine core for powering commercial aircraft are carried out now. For new aircraft and helicopters a development of turboprop and turboshaft versions of the AI-8000 with a power of 7000-8000 hp is under studying.
A small-size turboshaft engine, AI-450, rated at 465 hp is designed for powering Ka-226 helicopter. Experimental batch of engines was manufactured at Motor Sich, JSC. The AI-450MS auxiliary gas turbine engine to power a regional An-148 aircraft is based on the AI-450 engine core, and a modified version, AI-450M, with a rear shaft output (400 – 465 hp) for upgrading Mi-2M helicopter is under development today. It is undergoing bench testing, and a preparation of series production is in progress. In addition, an uprated version AI-450-2 (630-730 hp) to power helicopters of Ansat type, AI-450C (400-465hp) and AI-450C-2 (630-730 hp) turboprop engines are also developed for light airplanes of Yak-18, Yak-152, SM-92T “Finist Turbo”, EV-55 type, as well as, modified versions of turbofan engines AI-450BP (409 kgf) and AI-450-2BP (560 kgf) for light multipurpose airplanes and UAVs.
By using a great experience gained in the development of AI-222-25 , AI-222-25F and D-27 engines the AI-9500F with a thrust of 9.5 tons of force is under study for using as integrated in the power plants of light combat airplanes.
Requests for proposal on advanced engines, AI-40 (3500-4500hp), to power commercial airplanes are under development.
New materials, control systems, elements and components developed on the basis of new concepts and prospective technologies are under investigation now at the company. The developed and evaluated ideas, technologies and materials are introduced not only in the new advanced engines, but also while modifying the existing serially produced GTEs, that provide new possibilities and a quality improvement of aircraft performance.
For increasing a weight-lifting capability and efficiency of An-124-100 transport aircraft a modified version of D-18T series 4 engine with a maximum take-off thrust of 25830 kgf is developed. The new An-124-100M-150 aircraft will be able to carry cargo of up to 150 tons.
For upgrading the Czech AeroVodohody L-39 trainer an engine modified version, AI-25TLSh, was developed as based on the AI-25TL. A combat mode of increased maximum thrust up to 1850 kgf is introduced. Installation of the modified engine extends a service life to L-39 aircraft by 10-15 years. In December 2008, the engine installed in L-39 airplane has undergone the state flight tests. Today, the upgraded L-39 airplanes enter AF of Ukraine.
Gas Pumping Unit
The company’s designer team is developing the gas turbine drivers of industrial application. This line of activities enumerates 21 types of engines with a power ranging from 0.5 to 25 MW. The gas turbine drivers (GTD) of the D-336 family, rated at a power ranged from 4 to 10MW, and the AI-2500 with a power of 2.5MW are operated as integrated in 135 units in use at more than 31 compressor and 3 power stations in Ukraine, Russia, Belarus, Azerbaijan, Turkmenistan, Uzbekistan, Bulgaria, Turkey and Iran. All GTDs in operation have Certificates of Compliance awarded by certification centers of Russian Federation and Ukraine.
Power Station AI-2500
GTDs of SE IVCHENKO-PROGRESS design, rated at 2.5 MW, are operated as a part of electric power generating installations in tens of countries of the world, and, today, their derivative, the AI-2500, is extensively used both in Ukraine and Russian Federation.
Our company has designed a free turbine module, MST-198, a self-contained unit integrated in the modular gas turbine power-generating installations rated at 20 MW. Now it is under operation in Belarus and Russian Federation.
The SE IVCHENKO-PROGRESS’s latest development, AI-19GIG inert gas generator, has been designed for suppressing and localizing fires in tunnels, cable wells and in closed and semi-closed rooms of any type. A batch of the units has been delivered to South Korea, where their consumer’s characteristics acquired a high assessment. The next units of the AI-19GIG unit mounted on a truck chassis are manufactured.
R&D activities are carried out at the company on the development of a gas-pumping unit of a modular-container design, AI-45, rated at a power ranged from 0.5 to 1MW, a gas turbine driver AI-12N with 12MW of power and combustion chamber module for a 65 MW power station.
The company’s staff is an active participant in such international programs as: a program of development of light passenger aircraft of the Consortium of “Integrated Cesar Project (Cost Effective Small AiRcraft”) (with headquarters in Brussels, Belgium), EV-55 administrative airplane (Czech Republic), L-15 advanced trainer (powered by engine with afterburner) (China). It also participates in a delivery of technical documents and organization of production of a regional An-140 aircraft with engine in I.R.I.
The company offers to its Customers the services on mounting and maintenance of the gas turbine drivers, and also a personnel training at sites.
The company’s specialists perform the analysis of peculiarities of a driver operation at a particular compressor station, interactions between the stationary systems and GTD systems, make corrections in algorithms of the GTD control and adjustment, and also perform a personnel training in fast troubleshooting and elimination of abnormal situations occurred while operating. Similar procedures ensure a continuous operation and permit to improve consumer’s characteristics of GTDs.
A powerful intellectual, production and scientific-and-research facility of SE IVCHENKO-PROGRESS allows us to design gas turbine engines within a wide range of thrusts and powers.
The designer team and production section of the company work with using latest technologies. Today, SE IVCHENKO-PROGRESS possesses advanced technologies of designing and production. High-effective CAD/CAM designing and 3D calculations carried out on modern computer equipment, turbine single-crystal blades with a high-effective cooling system, compressor high-loaded stages manufactured by using a blisk technology (a disk integral with rotor blades), high-strength powder and granular alloys, composite materials and other advanced technical solutions are used today at our company for the development of new engines with high operating features.
The experimental and research facility of the company is one of the most powerful in Europe. It numbers 17 test benches and 78 rigs used for solving various problems related to the tests of engines, their per-component development, researches carried out for certification and further improvement of the design, reliability and fuel-effectiveness of the engines, etc.
SE IVCHENKO-PROGRESS carries out a common technical and marketing policy together with the Ukrainian and Russian manufacturers of gas turbine equipment. At present, the company has over 500 business partners, among which the majority are aviation enterprises of Russian Federation and Ukraine.
The gas turbine engines manufactured according to the SE IVCHENKO-PROGRESS documentation are successfully operated by numerous airlines in the world. The company maintains close interrelations with many of them, while offering services on overhauling the engines and ensuring the engine operation on technical condition. The company has a reputation of a serious and reliable partner among such airlines as Volga-Dnieper, Antonov Airlines, Anymex, Polyot and plus nearly 50 operators of the world.
Today, the company looks with confidence in the future, it has everything to be one of the world’s leaders in the development of modern, reliable, ecologically friendly engines. This is ensured by its own designing school, its team of highly skilled specialists, splendid resource base, and, certainly, its honest, mutually beneficial relations with partners and users.