How to produce aircraft engines in Russia

• How to produce aircraft engines in Russia

How to produce aircraft engines in Russia

JSC "Ufa Engine Industrial Association" - the largest developer and manufacturer of aircraft engines in Russia. There are more than 20 thousand people. UMPO part of United Engine Corporation.

The main activities are the development, production, maintenance and repair of jet aircraft engines, manufacture and repair of knots of helicopters, production of equipment for the oil and gas industry.

UMPO serially produces turbojet engines AL-41F-1S for the Su-35S, engines AL-31F and AL-31FP engines for the Su-27 and Su-30, individual components for helicopters "Ka" and "Mi", al-gas turbine drives 31ST for gas pumping stations of OJSC "Gazprom".

Under the direction of association being developed for advanced engine fighter fifth generation PAK FA (Sukhoi PAK FA, T-50). UMPO involved in cooperation for the production of engine PD-14 to the new Russian passenger aircraft MS-21, the program of production of helicopter engines VK-2500, in the reconfiguration of the production engine RD for MiG aircraft.

Welding in habitable chamber "Atmosphere-24"

Interestingly engine production step is argon arc welding the most critical node in the habitable chamber, providing full tightness and accuracy of the weld. Especially for UMPO Leningrad Institute "Prometheus" is one of Russia's largest welding station established in 1981, consisting of two units' Atmosphere-24. "

How to produce aircraft engines in Russia

According to sanitary standards worker may spend no more than 4 in the chamber 5 hours per day. In the morning - check suits, medical control, and only then can you start welding.

How to produce aircraft engines in Russia

Welders are sent to the "atmosphere-24" in the light space suits. Through the first door of the gateway they are held in camera, they attach hoses with air, close the door and passed into argon chamber. Once it will displace air welders open the second door, enter the cell and start working.

How to produce aircraft engines in Russia

In the non-oxidizing environment of pure argon begins welding of titanium.

How to produce aircraft engines in Russia

A controlled composition of impurities in argon allows to obtain high-quality welds and improve the fatigue strength of welded structures, enables podvarki in the most remote locations through the use of welding torches without the use of protective nozzles.

How to produce aircraft engines in Russia

In full dress welder, indeed, like a cosmonaut. To obtain a permit to work in the inhabited chamber, the workers held a training course, at first they were full gear train on the air. Usually, two weeks is enough to understand, good man for the job or not - it can withstand the load not everyone.

How to produce aircraft engines in Russia

Always in touch with welders - expert witness for a while from the control panel.

How to produce aircraft engines in Russia

The operator controls the welding current, the system monitors the gas analysis chamber and the common state and worker.

How to produce aircraft engines in Russia

No other method of manual welding does not allow such a result, as welding in the habitable chamber. weld quality speaks for itself.

How to produce aircraft engines in Russia

Electron beam welding.

Electron beam welding in a vacuum - a fully automated process. In UMPO he carried on Ebokam installations. At the same time two or three welded seam, and with a minimum level of deformation and changes in part geometry.

How to produce aircraft engines in Russia

One specialist working simultaneously on several plants of electron-beam welding.

How to produce aircraft engines in Russia

Details of the combustion chamber, the rotary nozzles and nozzle vanes blocks require applying thermal barrier coatings plasma method. For these purposes the robotic system TSZP-MF-P-1000.

How to produce aircraft engines in Russia

Tooling

As part UMPO 5 tool shops a total of about 2,500 people. They are engaged in manufacturing of technological equipment. Here create a machine accessories, dies for hot and cold metals, cutting tools, measuring tools, molds for the casting of ferrous and non-ferrous alloys.

How to produce aircraft engines in Russia

Mold making for blade casting is performed on CNC machines.

How to produce aircraft engines in Russia

Now for the creation of molds need only two or three months, but before this process took six months and longer.

How to produce aircraft engines in Russia

An automated means for measuring detects the smallest deviations from the norm. Details modern engine and tools to be manufactured to extremely exact observance of all sizes.

How to produce aircraft engines in Russia

The vacuum carburizing.

Automating processes always involves a reduction of costs and improvement of the quality of work performed. This also applies to the vacuum carburization. Carburizing - the surface of the carbon saturation of parts and enhance their strength - using vacuum oven Ipsen.

How to produce aircraft engines in Russia

In order to service the furnace only one employee. Items tested thermochemical treatment for several hours and then become perfectly strong. UMPO experts have created their own program, which enables cementing with increased accuracy.

How to produce aircraft engines in Russia

Foundry

Production in the foundry starts with the manufacture of models. Of special compacted mass model for parts of different sizes and configurations with subsequent manual finishing.

How to produce aircraft engines in Russia

In the area of ​​manufacturing investment patterns operate primarily women.

How to produce aircraft engines in Russia

banding model blocks and obtaining ceramic forms - an important part of the process of the foundry process.

How to produce aircraft engines in Russia

Before filling the ceramic mold calcined in furnaces.

How to produce aircraft engines in Russia

calcined ceramic forms - it is waiting for further casting alloy.

How to produce aircraft engines in Russia

So ​​looks drenched alloy ceramic mold.

How to produce aircraft engines in Russia

"weight in gold" - is a blade with a monocrystalline structure. Technology of production of such a blade is complicated, but it works and expensive in all respects much longer piece. Each blade "grown" using a special primer of the nickel-tungsten alloy.

How to produce aircraft engines in Russia

The plot of wide processing hollow fan blade

For the production of hollow wide engine fan blades

PD-14 - driver install MS-21 perspective of civil aircraft -

, a special portion where cutting is performed and machining of blanks made of titanium plates, the final machining of the lock and the profile of the blade, including its mechanical grinding and polishing.

How to produce aircraft engines in Russia

On chetyrohkoordinatnom horizontal machining center introduced finishing technology end of the blade on the device, designed and manufactured in UMPO - the know-how of the enterprise.

How to produce aircraft engines in Russia

The complex manufacturing compressor and turbine rotors (KPRTK) - a localization available capacity to generate the principal components of a jet drive.

How to produce aircraft engines in Russia

The assembly of turbine rotors - a time consuming process requiring special craftsmanship. High precision machining connection "shaft-drive-toe" - a guarantee of long-term and reliable operation of the engine.

How to produce aircraft engines in Russia

The multistage rotor going into a whole it is in KPRTK.

How to produce aircraft engines in Russia

rotor balancing is carried out by representatives of a unique profession that you can fully master the only factory walls.

How to produce aircraft engines in Russia

The production of pipes and tubes To all motor units functioned smoothly - compressor discharge, the turbine spun, nozzle camouflaged or open, you need to give commands to them. "The blood vessels' plane of the heart are considered pipelines - is very different information is transmitted on them. In UMPO there shop, which specializes in the manufacture of these "vessels" - different-sized pipes and tubes.

How to produce aircraft engines in Russia

In the manufacturing of tubes mini-plant requires manual piece of work - some of the details are real handmade works of art.

How to produce aircraft engines in Russia

Many operations benders performs machine with CNC Bend Master 42 MRV. It yoke tube made of titanium and stainless steel. First, determine the geometry of the pipe by using a contactless technology standard. The received data are sent to the machine which makes the preliminary bending, or at the factory language - gib. After an adjustment gib and final tube.

How to produce aircraft engines in Russia

So look handset is already in the composition of the finished engine - they entwine him like a spider web, and each performs its task.

How to produce aircraft engines in Russia

Final assembly.

In the assembly shop of the individual parts and assemblies become the whole engine. It employs Smith the highest caliber.

How to produce aircraft engines in Russia

collected on different parts of the shop large modules are joined collectors together.

How to produce aircraft engines in Russia

The final stage of the assembly is to install reducers with the fuel-regulating devices, communications and electrical equipment.

How to produce aircraft engines in Russia

a mandatory check for alignment (to avoid possible vibrations), alignment, since all the parts are supplied from different departments.

How to produce aircraft engines in Russia

After the bearer test engine is returned to the assembly shop for disassembly, washing and fault detection. First product disassembled and washed with petrol. Then - the external inspection, measurements, specific control methods. Part of components and assembly units to be sent in the same inspection-shops manufacturers. Then the engine is collected again - acceptance tests.

How to produce aircraft engines in Russia

fitter assembles a large module.

How to produce aircraft engines in Russia

Locksmiths MCP perform the assembly of the greatest creations of engineering thought of the XX century - turbojet - manually strictly referring to the technology.

How to produce aircraft engines in Russia

Technical Control Department is responsible for the impeccable quality of all products. Controllers work in all areas, including - in the assembly shop.

How to produce aircraft engines in Russia

In a separate portion was collected rotary jet nozzle (ORS) - an important design element that distinguishes the engine AL-31FP from its precursor AL-31F.

How to produce aircraft engines in Russia

The resource works PRS - 500 hours, and the engine - in 1000, so the nozzle should be done twice.

How to produce aircraft engines in Russia

A special mini-stand verify nozzle performance and its individual parts.

How to produce aircraft engines in Russia

The engine, equipped with PRS, the aircraft provides greater maneuverability. The nozzle itself looks pretty impressive.

How to produce aircraft engines in Russia

In the assembly shop has a section, which displays the reference sample of engines that were manufactured and produced the last 20-25 years.

How to produce aircraft engines in Russia

The test engines.

aircraft engine test - the final and very important stage in the processing chain. In a specialized workshop conducted bearer and acceptance tests on stands equipped with modern automated process control systems.

How to produce aircraft engines in Russia

In the engine test is used automated information-measuring system, consisting of three computers connected to the same local area network. Verifiers control parameters of the engine and bench systems exclusively on the testimony of a computer. Real-time processing of the test results produced. All of the tests carried out information stored in a computer database.

How to produce aircraft engines in Russia

The assembled engine is tested according to the technology. The process may take several days, after which the engine disassembled, washed, defektiruyut.

How to produce aircraft engines in Russia

All of the tests carried out information is processed and issued in the form of reports, charts, tables, both electronically and in hard copy.

How to produce aircraft engines in Russia How to produce aircraft engines in Russia

Appearance test shop: once the test rumble woke the whole neighborhood, and now does not get out a single sound.

How to produce aircraft engines in Russia

Shop number 40 - a place where all the products UMPO sent to the customer. But not only - here performed the final acceptance of products, equipment, entrance control, preservation, packaging.

How to produce aircraft engines in Russia

AL-31F engine is sent to the packaging.

How to produce aircraft engines in Russia

Engine expects neat wrap in layers of packaging paper and polyethylene, but it is not everything.

How to produce aircraft engines in Russia

The engines are placed in them are designed for special packaging is labeled according to the product type. After packing the equipment goes accompanying technical documentation: passports, forms, and so forth.

How to produce aircraft engines in Russia

The engine in action!

How to produce aircraft engines in Russia