Participation of SE Ivchenko–Progress in the CESAR project approved and funded by the European Commission under the 6th frame programme (FP6)
CESAR (Cost-Effective Small Aircraft)
A cooperative project participated by 40 enterprises and organizations from 13 countries,
including Ukraine. Project duration: 36 +6months. Project start date: September 1st, 2006. Pro-ject Finish Date: August 31st, 2009 (extended to February 1st, 2010).
The CESAR project was focused on the development of a small-size commercial aircraft with advanced characteristics that enable such aircraft producers to be fully competitive on the world market. The project had the goal to establish a new concept for development of such an aircraft, using advanced technologies that make it possible to considerably reduce the time-to-market of the aircraft and decrease costs of development, operation and maintenance while improving safety, ecological effect, and passenger convenience . The CESAR project aimed at providing necessary engineering and theoretical data for an advanced wing, competitive and ecologically acceptable power unit, and new technologies for main aircraft systems to decrease operating costs and improve safety.
Responsibilities of SE Ivchenko-Progress:
SE Ivchenko-Progress was responsible for the development of a built-in power unit for a small concept aircraft, namely design of an advanced turboprop engine. The development works in-cluded: the optimization of thermodynamic cycle and engine mathematical model; the develop-ment of small-size centrifugal compressor; the dynamic and structural analysis of; the develop-ment of high-speed turbo machines; the development of small-size cooled turbine, advanced shafting (gearbox). Moreover, SE Ivchenko-Progress participated in the creation of complex power unit control and technical conditions built-in diagnostic system, and on-condition mainte-nance systems.
Task of SE Ivchenko-Progress:
The main task of the power unit project was to develop technologies necessary for the creation of 200…400kW (270…550hp) built-in complex power units that are maximum acceptable for the aircraft, airline ant its clients. There was a number of sub-tasks to be addressed:
- reducing the power unit weight by 6 to 8% through the use of an advanced structure and a com-plex control system of the power unit;
- reducing specific fuel consumption by 2 to 3% through increase in efficiency coefficient of structural parts of engine;
- reducing the power unit dimensions;
- increasing the service life of engine and its systems by 10 to 15%;
- reducing maintenance costs by 7 to 9%;
- ensuring the safe operation of engine and its systems, and improving the flight safety.
In that way, the development of structures (concepts) and technologies necessary to support the creation of an up-to-date turboprop engine and its systems helped to reduce operational costs, enhance competitiveness of the consortium partners at the aviation market.
Participation of Ivchenko-Progress SE in the international project AERO-UKRAINE, approved and financed by European Commission within the 7th Framework Program (FP7)
AERO-UKRAINE – promotion of cooperation Ukraine – EU in the field of aeronautics research, support of Ukrainian aviation industry integration in the European structure.
The project involved seven enterprises and organizations from 4 countries, including from 4 countries, including 4 participants from Ukraine.
Duration: 24+6 months. Start of the project 01.04. 2009, end – 31.03.2011.
Object of research – potential participation of leading Ukrainian enterprises, universities in research programs of the EU 7th Framework Programme (FP7) in the field of aviation.
The main objective of the project – to promote scientific cooperation of European and Ukrainian aviation organizations.
Ivchenko-Progress SE role:
- Assessment of cooperation potential:
– with the EU in scientific researches for aviation organizations of Ukraine;
– with European aviation networks;
– mapping of aviation organizations of Ukraine;
– participation in the work on the formulation of “White Paper” on the aeronautics R&D in Ukraine.
- Support in AERO-UKRAINE web portal design, implementation and ongoing support.
- Holding an aviation event (seminar) in Ivchenko-Progress SE, Zaporozhye, 14.10.2010.
- Participation in aviation events in Ukraine (Kharkov, Kiev) and in the EU within FP7 (presentation of AERO-UKRAINE project and its aeronautics research on the “Aero-Days” in Madrid).
- Participation in the organization of a national contact point (NCP) for aviation in Ukraine.
- Information support for Ukrainian aviation organizations and companies on their inclusion in consortiums involved in the preparation of research proposals within the FP7.
Stages of scientific research work (SRW):
- promotion and support of cooperation between the EU and Ukraine in the field of aeronautical research;
- study and issue of a report (brochure) about the possibilities of Ukrainian aviation industry, containing a description of the major aviation organizations in Ukraine, analyses of the aviation sector, comparison between the priorities of the Ukrainian government and the EU in the field of aeronautical research, as well as recommendations for further scientific cooperation;
- organization of aviation event under FP7 in Ukraine;
- support for Ukrainian participation in FP7-AAT program (AAT – aviation and air transport);
- support in the organization of a national contact point (NCP) for aviation in Ukraine under FP7.
Theoretical and practical research results:
As a result of SRW the role of the government and leading organizations (companies) in the national aeronautics sector was shown, an overview of the main trends in the national sector of aeronautics research and technology was given, current and future prospects for aeronautics in Ukraine were studied, Ukraine’s participation in international aviation projects, recommendations to support EU-Ukraine cooperation were provided.
Participation of Ivchenko-Progress SE in the international project ESPOSA, approved and financed by European Commission within the 7th Framework Program (FP7)
ESPOSA (Efficient Systems and Propulsion for Small Aircraft)
Cooperative project in which 39 enterprises and organizations from 15 countries, including Ukraine and Russia, take part. Duration – 48 months. Start of the project 1.10.2011, end – 31.09.2015 (the term is prolonged till 11.03.2016).
ESPOSA project addresses development and integration of innovative design and manufacture technologies for gas turbine engines (GTE) rated at up to 1000 kW (1360 hp) in order to provide a wider range of advanced power plants for European aircraft manufacturers. In addition to that, the project will cover the systems related to engines that contribute to an increase in the efficiency of a whole power plant, to the safety and decrease of pilot work load. Through newly developed design tools and methodologies of engine integration with an airframe the project will also ensure better readiness of new GTE for the installation on an aircraft. New technologies and knowledge accumulated in the course of ESPOSA project implementation will create for general aviation (GA) of European industry significantly increased possibilities for creation and application of affordable and ecofriendly power plants and reliable aircraft systems providing minimal operating costs and higher level of safety. New power plants and engine technologies developed in the course of ESPOSA project implementation could ensure a decrease in direct operating costs by 10-14% and significantly reduce pilot work load. ESPOSA project is focused on GTE technologies designed specifically for 19-seat aircraft for scheduled and unscheduled flights. Research work includes increasing of engines major components performances and higher-quality and low-cost manufacture of these components. Innovative technologies applied in the engines components will be fortified with new advanced electronic engine control systems, innovate from the point of view of engine health monitoring in respect of small engines and providing more possibilities for propeller electronic control systems and fuel supply systems. The work on the project will includ an intensive validation on test benches and facilities. Functionality of specific outputs of the project will also be demonstrated and confirmed in flight conditions.
The role of Ivchenko-Progress SE in the project: leader of subproject on the development of optimal components for advanced baseline engine (BE1/BE2), designer of baseline engine No.2 (BE2/BE2+) rated at 400 … 470 kW (540 … 630 hp) power, leader of work packages – advanced mathematical modeling of GTE and validation of demonstrator engine BE2+ on the test bench.
The tasks of Ivchenko-Progress SE in the project: Development of a mathematical model, and execution of a trade-off analyses to assess the performance data of engine configuration (BE2/BE2+). Drawing up of a requirements specification and implementation of an optimization of BE2/BE2+ engine thermodynamic parameters in the system “aircraft – engine – propeller”. Development of draft technical requirements for BE2 engine components and systems, and draft control profile for BE2/BE2+ engine. Identification of an optimal design solution for high-pressure compressor. Experimentation on the optimization of high-performance, advanced small cooled turbine design. Dynamic modeling of an advanced high-speed turbo-machine. Drawing up of technical specifications on coatings for turbine, compressor, combustor parts, bearings mounting seats, and, after laboratory testing, assessment of demonstrators from the viewpoint of coatings quality and characteristics in real operating conditions; provision of comprehensive testing and assessment of BE2+engine on the test bench; verification of BE2/BE2+ engine mathematical model on the results of testing. Drawing up of a final statement on the possibility of BE2/BE2+ engines application on small 19-seat aircraft of GA.
Participation of Ivchenko-Progress SE in the international project OXIGEN, approved and financed by European Commission within the 7th Framework Program (FP7)
OXIGEN (Oxide Dispersion Strengthened Materials for the Additive Manufacture of High Temperature Components in Power Generation)
Cooperative project in which 11 enterprises and organizations from 6 countries, including Ukraine and Belarus, take part. Duration – 48 months. Start of the project 1.02.2013, end – 31.01.2017.
Gas turbine plants are the most advanced technology currently used in the field of power generation, providing the most efficient method of electric power generation. It is known that with an increase in the turbine inlet temperature one can substantially increase power generation efficiency. Today, the efficiency of a simple cycle gas turbine plant is approximately 40%, while the efficiency of a closed cycle gas turbine plant reaches 60%
To date, in the global market of power plants gas turbine drives the major parts and components, in particular compressor parts, are traditionally made of titanium and steel alloys, their mechanical and strength properties are used as much as practical and have reached their limit. With the toughening of requirement from power plant operators regarding reliability, efficiency, weight, service life, maintenance costs etc., the consumer characteristics of the plant as a whole and its individual components do not meet current standards and require new materials. Oxide dispersion strengthened (ODS) alloys developed within this project should allow a significant impact on the situation.
Ivchenko-Progress SE objectives in the project:
1) In order to demonstrate improved performance of the centrifugal compressor wheel of an advanced gas turbine drive (GTD), designed by Ivchenko-Progress SE, it was decided to manufacture it out of ODS titanium-aluminum alloy. The replacement of centrifugal wheel material alone will allow to achieve the compressor efficiency improvement by ~3% and reduce the specific fuel consumption of the engine by ~1%. In addition, reduction of centrifugal wheel weight (consequence of transition from steel alloy to ODS Ti-Al alloy) can increase the power of the entire plant.
2) The second aspect of research is a rotor blade (4th stage) of GTD turbine. Turbine blades experience a wide variety of loads during GTD operation. They are exposed to static, dynamic and cyclic loads, experience cyclic thermal stresses, they are operated in aggressive gaseous medium at high temperature and subjected to gas corrosion.
Currently, the creation of turbines with optimal weight characteristics requires the use of new alloys for LPT rotor blades that will reduce contour load on the turbine disk. In the design of rotor blades the development of intermetallic casting titanium-aluminum alloys is of great interest.
3) One of the methods for the manufacture of parts of intermetallic alloys is the method of laser sintering. So far, this method is a new and little known. In this connection a set of studies on the technology with regard to GTD parts is required.
The tasks of Ivchenko-Progress SE in the project:
– drawing up of requirements specification on physical and mechanical properties of new ODS-alloy and demonstrators configuration (centrifugal wheel, turbine rotor blade);
– modeling of demonstrators 3D-geometry;
– gas-dynamic and strength calculations;
– machining of demonstrators surface;
– testing of demonstrators on a bench under specified conditions;
– issue of a report on the results of demonstrators validation for the submission to European Commission.