Perpetuum mobile of the Russian military aviation industry
Created over forty years ago for the fourth-generation fighter, the AL-31F engine still meets the technical parameters of the best models in its class. The technological reserve built into this aircraft engine allows its continuous modernization. The AL-31F family has become a symbol of the stability of the domestic engine industry. The experience accumulated during the creation of this model range is used to develop a fundamentally new fifth-generation fighter engine, which will have even higher thrust and lower specific gravity.
General of the Army Sergei Shoigu quite naturally made his first foreign visit as Minister of Defense to the People's Republic of China. Military-technical cooperation (MTC) between Russia and China, which was extremely active at the end of the 20th century and seriously stagnated at the beginning of the 21st century, has regained a second wind in the last two years. At the heart of the new phase of the Russian-Chinese military-technical cooperation is the supply of aircraft engines, primarily of the AL-31F family. In the 90s, which were devastating for the entire Russian military-industrial complex (DIC), it was they who largely ensured the commercial success of the Su-27 / Su-30 multifunctional fighters abroad and thus saved not only the domestic military aviation industry, but also the engine-building industry in in general. Today, the developers of the AL-31F use all the accumulated experience and developments to create a fundamentally new engine for the fifth generation fighter T-50 (PAK FA is a promising front-line aviation complex).
For superiority over the F-15
The AL-31F engine developed by the Saturn Moscow Machine-Building Plant (now OAO A. Lyulka-Saturn, since 2001 part of OAO NPO Saturn) was chosen as the main one for the future fourth-generation Su-27 fighter, the main whose task was to achieve superiority over its American counterpart - the F-15. The decision to establish it was made in 1971. The corresponding conclusion of the Central Institute of Aviation Motors (CIAM) was made based on the results of an analysis of the operation of three engines - AL-31F, D-30F-9 and R-59F-300.
An experimental aircraft of the project called T-10-1 has been tested since May 20, 1977. Until 1982, nine such machines were built for this purpose with engines of the previous generation - AL-21F-3.
The development of a promising aircraft engine has been carried out since 1974. But the characteristics of the original version of the AL-31F (with two-stage high and low pressure turbines and low-load compressors) did not meet the tactical and technical requirements. The new bypass turbojet engine was created with an afterburner simultaneously with a complete redesign of the aircraft design. In fact, the T-10S fighter, newly developed by the Moscow Engineering Plant named after P. O. Sukhoi, had, among other things, significantly improved aerodynamic qualities and a different layout of the aircraft engine (drive box and all units in the upper part). On August 6, 1985, an act was signed on the acceptance of state tests of the AL-31F. The new engine with a thrust of 12.5 tons had single-stage high and low pressure turbines and highly loaded compressors. One of the key moments was the creation and implementation of JSC "A. Lyulka-Saturn "turbine blades of the cyclone-vortex system, which made the motor resourceful, before that it could be operated for no more than 70 hours. Work on the extension of the resource has become one of the main directions. Then the requirements of the Soviet Air Force were limited to 300 hours. At present, this indicator of the engine has reached a thousand hours.
The main manufacturer of the AL-31F was determined by JSC "Ufa Motor-Building Production Association" (UMPO). Then, the Salyut Moscow machine-building production enterprise (now FSUE NPC Salyut Gas Turbine Engineering) was involved in the program, which at first was engaged in the manufacture of individual engine elements. Over time, a kind of division of labor developed, according to which UMPO (leading in the subject) specialized in the production of elements of the cold part of the engine, and Salyut in the hot part. At the same time, the assembly was carried out at both enterprises.
Driven Vector
The AL-31FP engine with a rotary nozzle was first tested in 1989. In April 1996, an experimental model of the Su-35 fighter took off with a prototype of this motor with thrust vector control (UVT). In the course of work on this unit, special attention was paid to the effective control of the nozzle, a difficult task was solved by creating a reliable sealed joint between its moving and stationary parts. The resulting engine provided the world-renowned agility and reliability of the Sukhoi heavy fighters. Serial AL-31FP installed on the Su-30. The first foreign contract for aircraft with these engines was fulfilled by Ufa, which ensured the delivery of 40 Su-30MKI (80 engines) to India under a 1996 agreement.
During the 1990s, manufacturers of the AL-31F divided the markets with the help of informal agreements: engines for Indian aircraft were manufactured by UMPO, for export to China - by Salyut. As for other foreign customers, Algeria and Malaysia received Su-30 fighters with Ufa engines, Vietnam and Indonesia - with Moscow ones. The Venezuelan contract for 24 Su-30MKV2 plants was divided exactly in half.
Chinese contract
The events on Tiananmen Square in June 1989 put an end to the supply of Western weapons and military equipment to China. Because of the embargo, the Chinese program to create a national light single-engine aircraft J-10 was in jeopardy. The machine was created on the basis of the tactical fighter Lavi of the Israeli company Israel Aerospace Industries. The project was closed under pressure from the US in 1986 in favor of the F-16, but its developments were used by the Israelis in joint foreign programs.
Chinese J-10s were to be equipped with the PW-1120 engine specially developed for them by the American company Pratt & Whitney. But after the introduction of the embargo, this could be forgotten. As an alternative option, the Supreme Command of the People's Liberation Army of China chose a modification of the Russian AL-31F with a lower arrangement of units - AL-31FN.
The development of the first 14 engines for the Chinese project was carried out by A. Lyulka-Saturn" in 1992-1994 at the expense of the customer - the first precedent in the post-Soviet defense industry of Russia. The Russian Aviation and Space Agency has chosen the Salyut Moscow plant as the serial manufacturer of the AL-31FN.
Royalty controversy
Saturn entered into licensing agreements with UMPO and Salyut on monetary compensation (royalties) to him as a developer, according to which he receives eight percent of the cost of each engine sold - about 250-300 thousand dollars. Its price rose over time from $2.5 million to $3.5 million. In the case of the AL-31FN, the Salyut management, having received, by agreement, incomplete technical documentation for the engine, decided to finalize it to the level of mass production. Moreover, in 1999, the general director of the enterprise, Yuri Eliseev, concluded a license agreement with the Federal Agency for the Legal Protection of the Results of Military, Special and Dual-Use Intellectual Activities, effectively rewriting the rights to manufacture the engine for Salyut and thus leveling the agreement with Saturn, which receives royalties only from UMPO.
key element
The export dynamics of the AL-31F family has long acquired an independent (from the supply of combat aircraft) character. This is especially noticeable in the context of the Russian-Chinese military-technical cooperation. AL-31FN has become a kind of litmus test for assessing the state of the engine building of the Middle Kingdom. If in most areas the Chinese defense industry is constantly demonstrating serious success, then on the engine-building front, the Chinese are not yet able to establish mass production of a reliable engine for a combat aircraft.
That is why the PRC still continues to purchase AL-31F series engines for the light J-10, as well as for the heavy J-11B / BS (a copy of the Russian Su-27 fighter). In 1996, China acquired a license to manufacture 200 Su-27SK aircraft without the right to re-export to third countries. By the end of 2007, 105 of them had been collected. Then Beijing abandoned the further implementation of this licensed program, creating its own clone - J-11.
Russian engines are purchased by the PRC with the formal presence of the widely advertised domestic turbojet bypass WS-10A Taihang, designed specifically for the J-10 and J-11. But this motor is characterized by a low resource and a large number of design and technological shortcomings that have not yet been eliminated. According to official data, serial production of Taihang should be deployed before the end of 2015, but these terms seem overly optimistic.
China's attempts to overcome its "motor dependence" on Russia have so far failed. In 2009, China resumed purchases of AL-31F/FN engines. Moreover, the growth of Chinese orders is so high that the Federal State Unitary Enterprise "SPC Gas Turbine Engineering Salyut" barely has enough production capacity - almost 400 units were contracted in 2009-2011 (the entire volume of orders and deliveries is approaching a thousand). Another 140 AL-31FNs are to be delivered to UMPO under a 2011 contract to replace exhausted engines of J-11 (Su-27/Su-30MKK/MK2) multifunctional fighters.
Power characteristics are improved
According to Vladislav Masalov, General Director of the Salyut Gas Turbine Research and Production Center, Vladislav Masalov, the power characteristics of the AL-31F no longer fully meet the parameters of the technical specifications for the Su family aircraft, which should enter service with the Russian Air Force. First of all, we are talking about the new serial Su-34 front-line bombers and deeply modernized Su-27SM multifunctional fighters. The thrust of the more powerful version of the AL-31F-M1 engine (42nd series) created by Salyut has been increased to 13.5 tons without changing the overall dimensions. This motor is already supplied serially for the Su-27SM. In addition, it will be used for the remotorization of the Su-27, Su-30, and also, possibly, for the 19 remaining Su-33 shipborne fighters of the air group of the heavy aircraft-carrying cruiser Admiral Kuznetsov.
The next stage is the AL-31F-M2, which is planned to be put into serial production next year. According to the results of tests at CIAM, the possibility of increasing the maximum thrust to 14.5 tons with a decrease in specific fuel consumption, including in non-afterburning modes, was confirmed. The assigned resource is three thousand hours. Its installation will not require any modifications in the design of the airframe or engine nacelle of the Su-27SM or Su-34 engine and can be carried out directly in the troops.
Engine for PAK FA
After long discussions and struggle for the right to be the lead developer of the engine for the PAK FA, by the decision of the country's leadership, this engine is being created within the framework of the United Engine Corporation (UEC) with the distribution of areas of responsibility. Salyut, which is not part of the corporation, is a co-executor of the UEC.
The two main competitors were developing their parallel engine prototypes for the fifth generation fighter - Yeniseysk-A was led by Saturn, Yeniseysk-B was led by Salyut. The final winner has not been officially announced.
In the meantime, prototypes of the T-50 are being tested on the AL-41F1 - “product 117” jointly developed by OAO NPO Saturn, OAO UMPO and OAO Sukhoi Design Bureau. It is based on the same AL-31F. Some elements are borrowed from the developments on the creation of the “117S product” (AL-41F1S) for the Su-35 4++ generation fighter. The thrust of the engine "117" of the first stage for the PAK FA reaches 15 tons, it has a turbine with an increased diameter, all-angle thrust vector control, and a digital automatic control system. A full-fledged fifth-generation engine will have higher thrust and lower specific gravity. The exact parameters, as well as the development process itself, are kept secret. In any case, according to official statements, Salyut and Saturn are working on the project in close contact.
TRDDF (Turbojet dual-circuit engine with afterburner) AL-31F was sent to the Design Bureau of A.M. Lyulkin and the engine was purchased from a Tozi type in the USSR for lighting. When creating this, it is likely that information from "General Electric F110-GE-400". Assuming that the American engine got into the USSR in 1979, the trace of the Iranian revolution from February 11, 2019. Tova dava tlask in development for the deputy on AL-21F.
AL-31F has a modular design and is based on block 14, which somehow allows for forestry repairs and assimilation into separate parts during mass production. The engine has a four-stage adjustable compressor behind a low thrust, a low-rate compressor for a high thrust with an adjustable first degree, a single turbine for a low and high thrust with a cooling and adjustable radial spacing, a compact wall-shaped chamber behind the burner and an adjustable swirling-expanding nozzle. It is cooled on turbinite, made from a high-temperature alloy, giving the possibility of increasing the operating temperature and putting pressure on the engine, which significantly improves the performance. Obtaining a motor and a small mass and a high specific power.
Take two prototypes on the Su-27 (T10-1 / first flight on May 20, 1977 / and T10-2 / first flight on May 16, 1978 /), in order to file a deadline for the production of the engine, those sa AL-21F-3. Following the prototype, it was decided that everything would be produced with a golem size, such that, as a result, a new engine was installed.
Parviyat engine AL-31F e sgloben prez August 1984. Vednaga from him zapochvat from food, which will confirm the high characteristics of the product. Parallel to this work and a series of engines, together with the prototype. First, from series 01, they will be produced until the beginning of 1985 and no one has been put on the "combat machine". The only exception is the serial Su-27 board 23
, which is for 60 IAP, baziran on Dzemgi. The end of the end of October 1984 and betrayed it trembled and camped on November 7 this year. It was canceled for the sake of fun on the engine test, so why not change it from the second series.
The engine is from the second series and then it will work in two modes - normal operation and slaughter. Razlikata e in the draft. With the engine from the third series (behind the deck of the Su-27K), the third mode with a thrust of 12800 kilograms was also introduced.
Help for series
01 to start in 1985 about 30-40 bros. (100 hours before repair and 200 hours before rejection)
02 from 1985 to 1991 about 850-880 bro.(300 hours before repair and 600-900 hours before rejection)
03 from 1988 to 1993 about 80-100 bro.(200 hours before repair and 400-600 hours before rejection)
20 from 1991 to 1993 approximately 800 bros (same as 02)
22 of 1992 due to wear and tear
30 from 1993 to the present day producing over 400 engines primarily for machine repairs
42 from 2004 to the present, producing over 200 armor for modifications and new aircraft
Ruskite engines are produced in two factories, ss answer the factory code
Federal State Unitary Enterprise "SPC Gas Turbine Engineering Salyut" code 410
JSC "UPMO" code 3010
The next two numbers indicate the type of engine
99th main engine type
96th modification for the Su-30 AL-31FP with controllable vector for tractors
39th modification of the AL-31FN and all entitlement to manufacturers made in China
The next two digits mean the trim month and the year of production, first from 34, which means the third trim month for 1984.
Poraditova, che eventually biha repeat the number of the tax for the next 91 years, se tax and take additional measurements. Those sa combine in the next 2 digits, which means series. Such, for example, is the first series 01, followed by the series e 02. If exhausted, it will continue from series 20 after 1991.
The last three digits of the engine number are from 001 to 999.
Here are two examples with real engines for fighter jets that went through pre-repair in Ukraine.
410 99 36 02 091
The engine was produced in the Federal State Unitary Enterprise "SPC Gas Turbine Engineering" Salyut "" code 410
Basic type AL-31F code 99
Date of production third trimester of 1986 code 36
Series on engine code 02
Reduced serial engine code 091
3010 99 10 02 332
The engine was produced by JSC "UPMO" code 3010
Basic type AL-31F code 99
Production date first three months for 1990 code 10
Series on engine code 02
Reduced serial engine code 332
Nai-stariyat is known for the engine No. 410992502047 (47th from series 02, ed.) and e beat Montiran in Ukrainian board 06
factory number 369110
11910 first flight October 29, 1985, scheduled for November 11 this year on 831IAP. Hidden from flight prez 1995 for the sake of 300+ hours and technical condition. Given on January 30, 2001 to Moscow for repairs. The fighter was given overhauled prez 2003 by the Air Force.
Km of the moment (April 1, 2014) with about 4000 new engines from the AL-31F type for more than 1420 aircraft from the Su-27 family (Su-27 / J-11A /, Su-27UB, Su-30, Su-33 , Su-34 and Su-35), such as about 400 engines for the J-10A and about 100 wear for China, additionally making a reservation for 1992. Production of over 1000 repair kits. The total cost of spare parts per product is estimated at over 20-21 billion dollars. Prez august tazi year, rusnats will still whiten 30 years from the construction on a prototype prototype. Hi-many engines over 1000 sa wear for China. Somehow, in general, from about 400 sa AL-31FN for Chinese J-10A aircraft. For tyah sa wear and about 200 repair kits, the total costs for parts and engines are estimated at 1.6-1.7 billion dollars. Sega Russia continues and for China, the assembly of modernization of the AL-31FNM engine was put on the base of the 42nd series. Negotiate for 140 and try to get to the edge for 2015. Osven on the new J-10V fighters, the new engine was modernized from the Chinese, and put tests on the new J-15 and J-16 tech fighters, as well as on the J-20 generation of fighters from the peto generation. The draft for the receipt of the Russian engine is 13500 kilograms, with 1000 hours before repair and 2000 hours the stomach is assigned. The Chinese will put a new electronic control system on the engine. As a result, for some reason, the load has been increased to 14,500-15,000 kilograms, and the ima of the opportunity is even more, but sorting it all out, standing for an estimate on a small resource. Over 630 sa, use the AL-31F engines in China for the Su-27, Su-27UB, Su-30MKK and Su-30MK2 fighters, and send them to the country 105 J-11A. The period of recognition in Rusnacite from 2003 to 2010 is the year of repair kits not from wear. In spite of Comrade Ima, unofficial information for wear of about 100 repair kits from Russia from a period of time, such as over 100 from another country (Ukraine) in time on a spiran for wear from Moscow. The total cost for AL-31F engines and spare parts for tyah in Rusnacite for China is estimated at over 3.5 billion dollars or from wear on the AL-31FN at over 5.1 billion dollars. At the time of the current and second contract, due to which JSC "UPMO" has worn out a total of 150 engines to the edge for 2015, or the total wear has reached over 1310 engines and the cost of reserve parts to the edge for 2015 is estimated at about 7.9 billion dollar. Parsing everything, without a name, new deliveries are growing more and more and following the estimate for delivering parts.
Spore source from the Federal State Unitary Enterprise "NPTs Gas Turbine Engineering" Salyut ", the enterprise that has worn out about 1000 engines from the AL-31F family for China. Is there a date for the date?
On the second place in case of wear on the engine e India with over 440 engine and kit, as well as about 100 spare kit for repairs. The total cost is estimated at over 1.7 billion dollars. Indian quote and agreement for over 610 engines and AL-31 kits and options.
In the third city of Algeria with over 100 engine receipts. Until now, go to the country for engines and reserve parts for over 400 million dollars.
With about 100 engines for the fourth place in Vietnam, but don’t go away like golems, for the sake of it, you’ll use it for more than a year and 600 million dollars.
reference
Spored unofficial information for the last 123 AL-31FN engines, Chinese people paid 500 million dollars, some about 4 million per engine, for the last 150 from AL-31F about 700 million. For the purchase of 140 AL-31FNM1 engines, they paid 700 million, or about 5 million per engine. Osven spomenatata veche a sum of half a billion dollars for the development of 5 prototypes on the AL-31FNM2 sa paid 40 million dollars or 8 per engine. Probably serialize more in Evtini about 6-7 million dollars. It is not known to break the engine for the tosi agreement, but probably about 200. It is possible that about 25% of the engine is for the Chinese Su-35.
AL-31F M2 debuts in Zhukovsky
29.06.2012
One of the premieres of the TVM-2012 forum was the demonstration of the improved AL-31F M2 jet engine. It was created as part of the second stage of the modernization of the engines of the Al-31F family, which is being carried out by the Salyut Gas Turbine Engineering Research and Production Center.
The first stage of modernization of the AL-31F engine was completed in 2006. Then its thrust in a special mode was increased to 13,500 kgf. Now the AL-31F M1 engine (42nd series) is used on Su-27SM and Su-27SM2 aircraft, which are in service with the Russian Air Force.
Compared to the previous version, the engine thrust of the second stage of modernization in a special mode was increased to 14,500 kgf. The assigned resource has been increased from 2000 to 3000 hours. The AL-31F M2 is equipped with a specially developed FADEC-type digital automatic control system with a full hydromechanical reserve for controlling the main engine circuit, which will allow the engine to be adapted to any “board”, both analog and digital. In addition, the engine received a low-pressure compressor of increased efficiency and pressure, a reinforced intermediate casing, a combustion chamber with a tunnel-cooled flame tube, a more efficient turbine, a starting system without oxygen make-up and an improved oil system.
“Modernization of the AL-31F engine is carried out without changing its overall dimensions and is aimed at maintaining the possibility of re-engineering the entire Su-27 aircraft fleet both for the Russian Air Force and for foreign customers, without additional changes to the aircraft airframe or engine nacelle, entailing an increase in costs, - explained the general director of Salyut Vladislav Masalov. “Equipment of Su-27 family aircraft with modernized engines with such characteristics will significantly improve their flight performance.”
Bench tests of the AL-31F M2 engine on the ground and high-altitude tests in the CIAM thermal chamber confirmed the compliance of its characteristics with the declared parameters. According to the developers, tests are currently underway to confirm the initial resource, as well as the production of engines for flight tests. In addition, in cooperation with the United Engine Corporation, Salyut is working on a promising power plant for the fifth-generation fighter PAK FA.
Maxim Pyadushkin
Comment:
On October 31, 2013, Sergey Shoigu, Deputy Chairman of the Central Military Council of the People's Republic of China, Colonel-General Xu Qiliang, visited FSUE Gas Turbine Engineering Research and Production Center Salyut as part of an official visit.
Dispute unofficial source China terminated the contract for the development of a series of engines AL-31F M2. I paid a sum for the development of the engine (unofficially between 300-500 million dollars, or maybe even more). China E got the Prez November 2013 ni-malko 5 engine from the trial series. A trace of the test on one of them, two sabers were put on a new board 2011 on a fighter from a peto generation J-20. The new engine has been digitally controlled and extended from 2000 to 3000 hours. Programmatically osigurevane allowed yes, all the weights of the tractor, sometimes in the normal mode, 14,500 kilograms. Say, if possible, reach up to 16,500 kilograms, for some reason they allowed the Chinese to continue working on the consumer until mass production on the engine.
The AL-31FN engine of series 3 manufactured by the Federal State Unitary Enterprise NPC Gas Turbine Engineering Salyut was assigned the letter O1
On April 10, 2014, the design documentation for the AL-31FN series 3 engine was approved as serial production documentation with the assignment of the letter "O1".
A set of works was carried out at Salyut to ensure the supply for the Customer (PRC) of AL-31FN series 3 engines intended for use as part of the J-10 aircraft:
– long-term equivalent-cyclic tests of the engine were carried out according to the planned program for an initial resource of 750 hours. During the tests, the characteristics of the engine, the operability and reliability of all systems and units and the service life of 750 hours before the first repair were confirmed. The AL-31FN series 3 engine complies with the requirements of technical specifications;
- special tests of the engine with strain gauges of the blades of the 1st and 2nd stages of LPC were carried out at the enterprise's stands, as well as a check of the absence of self-oscillations of the rotor blades of the 1st stage of the LPC in the TsIAM TBK with simulation of flight modes. The results are satisfactory.
In addition, according to the plan agreed with the customer’s representative (PZ), special tests were carried out at a gas temperature increased by 25K in front of the turbine, engine performance was evaluated at rotor speeds 3% higher than the maximum allowable, new pipelines were strain gauged, and interdepartmental tests of the TsRD-99 digital engine controller were carried out. The test results are satisfactory.
On the basis of GP 156, flight tests of the AL-31FN series 3 engine as part of the J-10 aircraft were carried out. According to the results of flight tests, the Act dated 12/27/2013 was approved with GP 156. The results are satisfactory, the engine meets the requirements of the technical specifications.
FSUE CIAM issued a Conclusion on the strength of the AL-31FN series 3 engine for a service life of 750 hours / 1000 flight cycles before the first overhaul for operation on the J-10 aircraft at the Customer.
To organize serial production of AL-31FN series 3 engines at the Salyut Research and Production Center for Gas Turbine Engineering, by the decision of the Head of the Department of the Ministry of Defense of the Russian Federation for the State Defense Order (GOZ), an interdepartmental commission was created to check the readiness of design documentation (CD) for approval and assignment of a letter "O1" (serial production documentation).
At the Federal State Unitary Enterprise "SPC Gas Turbine Engineering" Salyut ", which presented the design documentation, the interdepartmental commission carried out checks:
- compliance of the submitted design documentation with the requirements of technical conditions;
- completeness of the adjustment of design documentation based on the results of manufacture and tests of engines;
- compliance of the design documentation with the requirements for completeness, content, design, quality condition of the originals and their suitability for reprography;
- the level of unification of the engine with the prototype engines AL-31F series 42 and AL-31FN series 1, 2;
- compliance of design documentation with current production;
- conformity of the used purchased components (PKI) in terms of warranty periods and operating conditions, as well as compliance with documents authorizing their use as part of the engine;
- availability of calculations and documents for strength and reliability tests, test programs and regulatory documents for standardization, agreed with the PZ;
- availability of application authorization protocols;
- the presence of a technological process for assembling the engine;
- technological readiness of production for the production of engines;
- availability of lists of sets of spare parts and accessories (spare parts and accessories) and special tools;
- completeness of the SPTA engine in accordance with the list of SPTA and special tools;
- providing the engine with measuring instruments for checks in operation;
- meeting the requirements of electromagnetic compatibility as part of an aircraft (AC) with aircraft systems and airfield equipment;
- indicators of unification of technological processes with prototype engines;
- certification of test equipment according to GOST.
By the decision of the Head of the Department for Ensuring the State Defense Order of AT and B of the Department of the Ministry of Defense of the Russian Federation for Ensuring the State Defense Order dated April 10, 2014, the Act of the IAC on verification of the design documentation was approved. The design documentation for the AL-31FN series 3 engine was approved as serial production documentation with the assignment of the letter "O1".
Currently, work continues to ensure overhaul and assigned engine resources. The engine undergoes lengthy tests for a TBO of 750 hours.
On the basis of the Customer (China), the operation of the first production J-10 aircraft with AL-31FN series 3 engines manufactured in 2013 begins.Copyright 2014
Evgeny Semivelichenko appointed Managing Director of UMPO
Evgeny Alexandrovich Semivelichenko, who previously held the position of Deputy Managing Director of UMPO OJSC (part of UEC JSC) for corporate and legal issues, was appointed to the position of Managing Director of UMPO OJSC. The appointment order was signed by the General Director of UEC JSC Alexander Artyukhov on September 8, 2015.
E.A. Semivelichenko was born in Ufa in 1978. In 1997 he graduated from the Ufa College of Statistics, Informatics and Computer Engineering with a degree in Economics, Accounting and Control, and in 2000 he graduated from the Bashkir State University with a degree in Jurisprudence.
Evgeny Alexandrovich has been working in the Ufa Motor-Building Production Association since 2003. He started as the head of the legal department. Since 2008, he has been Deputy General, and since 2011 - Managing Director of UMPO for corporate and legal issues
Salyut continues to increase production volumes
28.02.2017
In 2016 JSC "SPC Gas Turbine Engineering Salyut" fulfilled the state defense order for the manufacture of new engines and repair of products for the Ministry of Defense of the Russian Federation.
The results of the work of the enterprise in 2016 became an indicator of the high potential of the experienced team of Salut workers and the powerful production reserves of the plant. In the harsh conditions of tight deadlines, the Salyut employees managed to ensure the timely delivery of the main engines and fulfill their obligations to the Ministry of Defense in full, while mastering new types of products.
In 2016, Salyut Gas Turbine Engineering Research and Production Center JSC ensured a 5% increase in production volumes compared to 2015, as well as a multiple increase in production volumes through cooperation. All budgeted plans for these indicators were implemented in full. At the same time, the portfolio formed for 2017 orders allows us to predict a further increase in the volume of commodity output.
In 2016, Salyut continued to implement projects in cooperation with other enterprises of UEC JSC. This is the development of production, manufacture and delivery for testing of parts and assembly units (DSE) of the VK-2500 helicopter engine, TV7-117ST turboprop for the Il-112V, RD-33MK light military transport aircraft, which are installed on multifunctional fighters of the MiG family. The enterprise fully fulfilled its obligations under the PD-14 project for MS-21. The Omsk branch of the plant - "OMO named after P.I. Baranov" is included in the work on the NK-32 engine of the second stage for the Tu-160 strategic bomber.
The plant also participates in the production of components for a promising engine for PAK FA, produces DSE for marine engines. In 2017, for all these projects, the volumes will increase.
According to Vitaly Olegovich Klochkov, Deputy General Director, Managing Director of Salyut Gas Turbine Engineering Research and Production Center JSC, Salyut's participation in the program for manufacturing TV7-117ST/SM/V engine components is a priority activity within the framework of industrial cooperation. Within the framework of this project, in 2016, and shipped to the customer - JSC "Klimov" sets of the main four units: central drive, gearbox, upper and lower drive boxes. Taking into account modern trends in the organization of engine production and the tight deadlines for the implementation of this project, the strongest competencies of each of the sites are used in the production of TV7-117ST " Salyuta". The geography of internal cooperation on this product is very wide - in addition to the head Moscow site "Salute" and the branch "OMO im. P. I. Baranova, the Pribor Plant, VMZ Salyut, MKB Gorizont and a number of Salyut affiliated enterprises, such as Agat OJSC, Agregat OJSC, NFMZ OJSC with taking into account their specialization.In 2016, all the requirements of customers for the manufacture of DSE for the VK-2500 helicopter engine were met.During the year, compressor rotor kits were mastered in production and shipped, an axial compressor kit was prepared for testing and shipped.In 2017, a significant increase in serial deliveries is planned. kits for this engine, "Salyut" also entered the active phase of the program for the manufacture of the RD-33MK engine and modifications. The Salyut component in production is about 37%. Under agreements with the UEC, work continues on two promising projects of the holding - the creation of an engine for the PAK FA, as well as the production of units and parts for PD-14.
In addition, the company continues to implement projects traditional for Salyut. This is the manufacture and supply to customers of the AL-31F engines and its modifications for aircraft of the Su family, AI-222-25 for the Yak-130 combat training aircraft. In 2016, the plant fulfilled all obligations on these topics in full.
In the implementation of the AI-222-25 project, the task of increasing the resource and reliability of this engine comes to the fore. During the year, the enterprise provided the supply of new engines and repairs for the Ministry of Defense of the Russian Federation. Specialists of the directorate of research and development work of the enterprise increased the assigned resource of the AI-222-25 engine. They developed, tested and implemented the "Instruction for the modular replacement of engine components AI-222-25", which allows you to put engines into operation in the conditions of combat units.
As part of the development work, work is underway to produce and test components of a promising engine for the PAK FA. Tests of the AL-31FN series 03 engine were completed for the assigned resource of 2000 hours. On the creation of the SM-100 engine for the Yak-130 combat training aircraft, design documentation was issued and the production of the DSE SM-100 was launched, which is the task of 2017. Also, the implementation of these and other projects through research and development of the enterprise will continue in 2017. Also, in accordance with the production and supply plans, the main Salyut product is being manufactured - the AL-31 engine and its modifications - products "39" and "99", for which obligations to the Ministry of Defense of the Russian Federation were fully fulfilled in November 2016 within the framework of the state defense order. Next year, the implementation of contracts for these products will continue, including with China for the production of the AL-31FN engine for the J-10 fighter jet of the Chinese Air Force. Given that the increase in production capacity and the serial development of RD-33MK and VK-2500 products directly depend on the introduction of advanced equipment and technologies, mechanization and automation of production, outdated and worn-out equipment is being replaced with new, more productive equipment. During 2016, a significant amount of work was carried out in this direction: 43 units of new equipment were purchased and put into operation, and it is planned to receive 3 more units by the end of the year. In total, investments in equipment amounted to over 1 billion rubles.
In 2016, the company launched a project on the marine theme. In the branch of "MKB" Gorizont "tests of a gas turbine engine for ships and boats of the Navy were carried out. The start of the tests was given after the completion of the first stage of creating a unique test bench for gas turbine drives for various purposes under the import substitution program. More than 60 units of special equipment were purchased for the modernization of the stand for more than 200 million rubles Joint work on the marine theme with NPO Saturn is a new direction for Salyut as part of the transformation of the UEC industrial model. for the current year - the organization of effective work in order to implement large-scale projects within the United Engine Corporation. "To implement production programs in the creation of high-tech products and ambitious tasks, Salyut currently has all the necessary resources: a modern technological base, the latest neck equipment, and most importantly - a highly professional team capable of creating competitive products and having vast experience, this year the legendary, oldest enterprise in the industry turns 105 years old," summed up V.O. Klochkov.
AL-31FN series 4 engine for China?
April 13th, 2018
According to the publication " Air&Cosmos"in the material" Saliout propose la poussee vectorielle pour les J-10 chinois”, a new modification of the Russian AL-31FN series 4 engine can be installed on Chinese J-10 fighters.
During the International Engine Building Forum MDF-2018, which was held in Moscow on April 4-6, 2018, JSC United Engine Corporation (UEC) presented the AL-31FN engine with a deflectable thrust vector (OVT), developed at JSC Research and Production Center gas turbine construction "Salyut". The engine is offered to China for new modifications of the J-10 fighter
Salyut began studying OBT 15 years ago, initially with the assistance of Klimov Design Bureau. A prototype engine with an OVT - a KLIVT nozzle was installed on an experimental MiG-29M-OVT aircraft equipped with RD-33 engines. "Salyut" acquired the documentation for the CLIVT, but then seriously finalized it. As a result, according to the employee of the enterprise, "Our nozzle has nothing to do with CLIVT anymore."
The Soluta nozzle, like the KLIVT, is "three-dimensional". It can deviate 16 degrees vertically and 8 degrees horizontally. All plane deflection is important for a single engine aircraft like the J-10. On twin-engine aircraft (Su-30, Su-35, Su-57), the "three-dimensional" effect is achieved due to the correct installation of nozzles with movement in two planes. These aircraft are equipped with engines with OVT, the thrust vector of which can vary within +/- 15 degrees, which were developed in Lyulka Design Bureau.
Salyut's main source of revenue is the production of AL-31FN engines in various modifications for China. In 1992-2004, China purchased 280 Su-27 and Su-30 fighters, but then proceeded to produce their own J-11 and J-16 clones. The engines for these aircraft, with the exception of a few machines with Chinese engines, are produced by Salyut.
Salyut is the only manufacturer of AL-31FN engines specially designed for the Chinese Chengdu J-10 fighter. AL-31FN ("product 39") differs from AL-31F ("product 99V") in the gearbox located below ("N" - from "lower"). In 1997-1998, China received nine experimental AL-31FN engines for J-10 prototypes, and then about 400 engines for production aircraft (the first ten J-10s were produced in 2002).
Series 1 and 2 AL-31FNs were delivered to early production batches of J-10s. Their performance characteristics differ little from the base AL-31F, including thrust (12.7 tons in afterburner mode and 7.6 tons at nominal). Engines of the second series, produced since 2011, have an extended resource.
Since 2013, Salyut has been supplying China with the AL-31FN series 3 engines (Product 39M1), which are used in J-10B fighter jets. They are equipped with a new low-pressure compressor KND-924-4 with a diameter of 924 mm (early versions had a diameter of 905 mm) and a new digital engine control system KRD-99T. The maximum thrust of the engine reaches 13.5 tons, it has an increased resource. He received his certificate on April 10, 2014. Russian media reported that in 2012, China ordered 137 Series 3 AL-31FN engines.
Salyut currently offers Series 4 AL-31FN engines, which are identical to Series 3, except for the presence of OVT. Apparently, China has not yet purchased these engines.
In November last year, Rosoboronexport signed a major contract for the supply of 180 AL-31F engines to China for Su-27SK and Su-30MKK aircraft, estimated by experts at $550 million. , which traditionally supplies AL-31F engines to the Chinese market. The new order allowed Salyut to reach a record level of production over the past 15 years: the plan for this year provides for the manufacture of products worth 16.9 billion rubles. (about 600 million dollars), which is almost 90% of the production volume of the enterprise in 1991 - the last year of the existence of the USSR. 83% of Salyut's income is currently provided by export deliveries, however, the company is confident that sooner or later this ratio will change, and the upgraded versions of the AL-31F developed at Salyut for the domestic Air Force will find application on Russian military aviation fighters. Recently, our correspondents Petr Butovsky and Viktor Drushlyakov visited the Salyut MMPP and were able to get acquainted with the main programs of the enterprise.
Stages of modernization of the serial AL-31F, developed at the Salyut MMPP
"Salut" grows on Chinese "yeast"
Engines of the AL-31F family are mass-produced by two enterprises: MMPP Salyut in Moscow and UMPO in Ufa. According to the established tradition, export deliveries to China are the prerogative of Salyut, and the Indian Air Force is armed by UMPO. Deliveries of engines to other countries are carried out by both companies jointly. Since 1992, the PRC Air Force has received about 280 Sukhoi fighters into service: 76 Su-27SK and Su-27UBK, 76 Su-30MKK and 24 Su-30MK2 imported from Russia, as well as up to 105 J-11 (Su-27SK ), built under a Russian license directly in China. The first batches of Su-27SK and Su-27UBK arrived in China in 1992 and 1996, and it is for them that the new engines, for which Salyut recently received an order, are intended. The fact is that the assigned resource of the AL-31F, produced in the 90s. is 900 hours, and taking into account the intensive operation of the Su-27 in China, they already require replacement with new ones. Recall that having bought a license for the production of Su-27SK, the PRC did not receive the right to produce its own engines for them. True, China is developing its own WS10 engine of this class, but new large orders for the AL-31F and AL-31FN in Russia indicate that this engine is still far from mass production.
The November contract for 180 AL-31Fs was preceded by another major deal: four months earlier, in July 2005, Salyut received an order from China for 100 AL-31FN engines for the new Chinese J-10 fighters (see "Rise » No. 10/2005, p. 42). The first shipment to the customer took place already in October last year, and the delivery of the last batch of AL-31FN is scheduled for the third quarter of 2006. In addition, in early 2005, Salyut signed a three-year contract for the repair and supply of spare parts for previously built AL-31F engines.
AL-31FN (at the factory it is called "product 39") is specially designed for use on the J-10 aircraft. It differs from the base AL-31F (“product 99V”) by the lower location of the gearbox, while the main characteristics of the engine remain unchanged. Back in 1997, China purchased from A. Lyulka-Saturn" nine experimental AL-31FN engines, which were installed on the first prototypes of the J-10. The serial version of the AL-31FN appeared in 2000. Its development was carried out by A. Lyulka-Saturn", and further fine-tuning - KB "Salute". For the next prototypes and the first production J-10s, China ordered another 54 AL-31FNs. All of them were delivered in 2001-2003. to the Celestial Empire already "Salute". The program of the Chinese J-10 fighter is developing quite intensively, which means that Salyut may soon receive new orders from the “great neighbor” from the east.
For native Air Force
On June 23, 2000, the Russian government appointed the Rybinsk NPO Saturn as the lead developer and manufacturer of the power plant for the promising PAK FA fighter, which received an order to create an engine, now known under the conditional name "product 117C". The same engines are planned to be used on new modifications of the Su-27 family of fighters.
Salyut in this program was assigned only a modest role as a manufacturer of components and assemblies of the new engine, which is a deep modernization of the current AL-31F. The management of the enterprise could not come to terms with this, therefore, in the same summer of 2000, Salyut, on its own initiative, began a program of phased modernization of the serial AL-31F, which could become an alternative to the “product 117C”. This became possible thanks to the organization at the plant in early 2000 of its own Design Bureau for Advanced Development (KBPR).
The engine of the first stage of modernization developed at Salyut was named AL-31F-M1 (“product 99M1”). Unlike the serial AL-31F, it is equipped with a modified four-stage low-pressure compressor KND-924-4 with a diameter increased from 905 to 924 mm, as well as a new digital integrated engine controller KRD-99Ts. The increase in the performance of the AL-31F-M1 compressor can be used in two ways: on the one hand, it gives an increase in engine thrust by 6-15%, and on the other hand, it allows, with the same thrust, to reduce the temperature of the gases in front of the turbine by 35K, which significantly increases the engine life.
Flight tests of the 9th copy of the AL-31F-M1 on the flying laboratory LII Su-27 No. 37-11 (onboard No. 595) began on January 25, 2002. Later, two engines of this type were installed on this aircraft. In total, 27 flights with AL-31F-M1 engines were performed on the Su-27 No. 37-11 as part of flight design tests, in addition, by the beginning of this year, six out of ten planned flights under the state test program took place. State tests of the AL-31F-M1 should be completed in the spring of 2006, after which the engine will be considered ready for mass production and will be able to be installed on the Su-27 aircraft of the Russian Air Force during their repair and modernization.
Comparative data of AL-31F and AL-31F-M1 engines
| AL-31F | AL-31F-M1 | |
| High thrust mode | afterburner | |
| Thrust, kgf | 13 500 | |
| Specific consumption | ||
| fuel, kg/kgf*h | - | 1,96 |
| Gas temperature | ||
| before the turbine, K | - | 1690 |
| Air consumption, kg/s | 119 | |
| Full afterburner mode | ||
| Thrust, kgf | 12 500 | 12 500 |
| Specific consumption | ||
| fuel, kg/kgf*h | 1,96 | 1,97 |
| Gas temperature | ||
| before the turbine, K | 1665 | 1630 |
| Air consumption, kg/s | 113 | 114 |
| High thrust mode without afterburner | ||
| Thrust, kgf | 8250 | |
| Specific consumption | ||
| fuel, kg/kgC"H | Me and | 0,77 |
| Maximum mode | ||
| Thrust, kgf | 7670 | 7670 |
| Specific consumption | ||
| fuel, kg / kgf "h | 0,78 | 0,77 |
| Degree of bypass | 0,56 | 0,61 |
| Maximum diameter, mm | 1280 | 1280 |
| Length, mm | 4990 | 4990 |
| Dry weight, kg | 1547 | 1557 |
| Resource before the first repair, h | 500 | 1000 |
| Assigned resource, h | 1500 | 4000 |
Basic data of low-pressure compressors for AL-31F engines manufactured by MMPP Salyut
What's next?
At the beginning of 2006, Salyut began testing the engine of the next stage of modernization - AL-31F-M2 ("99M2"), which recently received a new name AL-31F-SM ("99SM"), emphasizing the possible scope of its application - modernized fighters Su-27SM. There are two main differences of the "second stage": these are new turbine disks and re-profiled compressor blades KND-924-4. Thanks to these modifications, the afterburner thrust of the AL-31F-SM increases to 14,000 kgf. It is important that the engines
AL-31F-M1 and AL-31F-SM are fully interchangeable with serial AL-31F used on Su-27 aircraft - you only need to install a spacer in front of the engine inlet, the need for which is determined by the increase in fan diameter. Moreover, the previously produced AL-31F can be quite simply brought up to the level of the upgraded AL-31F-M1 and AL-31F-SM by replacing individual modules during their overhaul.
In December 2006, Salyut expects to begin testing the engine of the third stage of modernization - AL-31F-ME ("99MZ"), which is distinguished by the use of a fundamentally new low-pressure compressor KND-924-3, a new combustion chamber and new turbine blades. The three-stage compressor KND-924-3 with wide-chord blades is made using the "blisk" technology. The innovations will make it possible to raise the thrust of the AL-31F-M3 to 15,000 kgf.
Above: The KND-924-3 three-stage wide-chord fan, developed by Salyut and using blisk technology, will be used on AL-31F-M3 engines
The rotary nozzle, created at the Salyut MMPP using the KLIVT technology (developed by the V.Ya. Klimov Plant) for the upgraded AL-31F engines, provides all-angle thrust vector control
Below: the AL-31F-M1 engine upgraded in the first stage, the state tests of which are being completed this spring
Is there a prophet in his own country?
It is no secret that the new modifications of the Su-27 family are, first of all, the Su-34 attack aircraft, the mass production of which has recently begun in Novosibirsk for the Russian Air Force, and the promising Su-35 multifunctional fighter for export deliveries, the testing of which should begin in 2006- 2007 need more powerful engines. The first Su-34s are still flying with serial AL-31Fs, but it is obvious that their thrust is not enough to realize all the potential capabilities of this 45-ton aircraft. Two types of modernized engines are suitable for use on such aircraft today: the “product 117C” developed by NPO Saturn and the AL-31F-M1 (or AL-31F-SM) developed by MMPP Salyut. However, Salyut's chances of getting an order for the remotorization of these aircraft should not be assessed as high: the Air Force entrusts the right to choose the power plant to Sukhoi, and, as you know, for a number of understandable reasons, it focuses on working with Saturn. Unfortunately, Salyut should not flatter itself too much about its participation in the modernization program for combatant Su-27s: so far, the Russian Air Force does not plan to replace the engines on these aircraft with modernized ones.
The chances of new Salyut developments on aircraft of the Russian Navy aviation can be estimated somewhat higher. All Su-33 naval fighters today are equipped with AL-31F series 3 ("99A") engines built by Salyut. Unlike the rest of the serial AL-31F series 2 ("99V"), they have increased thrust to 12,800 kgf in the so-called "special" mode of operation, which is achieved by a short-term increase in the temperature of the gases in front of the turbine by 75K. However, the use of such a regime does not pass without a trace for the engine: the resource of AL-31F ser. 3 is only 700 hours (for the first engines of this modification - and even more so only 300 hours), while the current AL-31F ser. 2 - 1500 hours, and for future AL-31F-M1 - 4000 hours. In addition, the recent accident and a prerequisite for a flight accident on board the Admiral Kuznetsov TAVKR that occurred in the Atlantic on September 5 last year (see "Rise" No. 10 /2005, pp. 44-47), clearly testify to the undoubted benefits of increasing the thrust-to-weight ratio of Su-33 fighters. In this context, Salyut is negotiating with the command of the Russian Naval Aviation on the possibility of re-engining combatant Su-33 aircraft with AL-31F-M1 engines.
However, in this case, the path of new "Salyutov" engines on board Russian military aircraft may not be easy. In such a situation, it will no longer be surprising if they find application much earlier on aircraft flying with red stars - but not domestic, but Chinese. Work in this direction is already underway. Salyut offers its AL-31F-M1s for the Chinese Su-27SK and J-11, Su-30MKK and Su-30MK2, as well as Su-33MK, which, according to experts, China may order from Russia in the near future to equip its first aircraft carrier.
Another version of the "Chinese" development of events is the use of the AL-31FN-M1 engine with increased thrust with an all-angle UVT on the new J-10 fighters. The prototype of the modernized AL-31FN-M1 ("39M1") was manufactured at Salyut in 2005, and this year the company plans to complete the full cycle of its testing.
At one time, in 2000, Salyut produced an experimental batch of ten AL-31FP ("96") engines with a UVT system designed by JSC "A. Lyulka-Saturn. Subsequently, serial production of the AL-31FP for the Indian Su-30MKI was mastered at UMPO, and Salyut took the path of introducing a different nozzle rotation control scheme, providing for the possibility of an all-aspect UVT. The basis was the position of the CLIVT technology, developed by the St. Petersburg "Plant im. V.Ya. Klimov" for modifications of the RD-33 engines used on the MiG-29 fighters and, again, the Chinese FC-1. In principle, for a twin-engine aircraft of the Su-27 or Su-30 type, thrust vector control in one plane, implemented in the AL-31FP engines, is quite sufficient. But in the case of a single-engine J-10, the advantages of an all-angle UVT turn out to be preferable. Therefore, Salyut acquired the documentation on the KLIVT system from Klimov, but then significantly revised it. Models of AL-31F-M1 engines with an all-aspect UVT have been demonstrated publicly since 2002 in Zhukovsky on Su-27 aircraft No. 595 and 598. The “live” rotary nozzle as part of the AL-31F engine is undergoing long-term testing at the MMPP stand "Salute" in Moscow. The developer claims that the life of the rotary nozzle, already confirmed by tests, currently reaches 750 hours, and in the near future it is planned to increase it to 1000 hours.
Testing of the AL-31F engine equipped with an all-aspect UVT nozzle at the Salyut MMPP stand
Not only for "Dry"
Another modification of the AL-31F, developed by the Salyut MMPP, is the AL-31F 30C series engine (“Product 53”), designed for the remotorization of Indian MiG-27M fighter-bombers. A proposal to equip the modernized MiG-27M with such an engine was submitted to India in June 2003, and recently this program received a new impetus: MMPP Salyut and RAC MiG agreed to jointly finance the conversion of a demonstrator aircraft for testing AL- 31F Ser. 30C. In September 2003, a model of such an engine was installed on the MiG-27M No. 01-01 aircraft, which was already non-flying by that time, and in March 2004 Salyut began bench tests of the first and then the second full-size AL-31F ser. 30C. Recently, the third engine of this type was assembled at the enterprise, already intended for flight tests. It is expected that the upgraded MiG-27M, equipped with this engine, will be able to take off in the second quarter of 2006.
Not AL-31F single
In addition to fulfilling major Chinese contracts for the supply of AL-31F, AL-31FN and the development of their upgraded versions of the MMPP, Salyut is actively involved in a number of other engine building programs today. For the Russian Air Force, in cooperation with Ukrainian enterprises, it is preparing for the mass production of new AI-222-25 engines for the Yak-130 combat training aircraft. In the same cooperation, since 1993, he has been involved in the manufacture of turbofan engines of the D-436 family for Be-200 amphibious aircraft, passenger Tu-334s and new regional An-148s. In case of winning the tender for the engine for the promising short-medium-range aircraft MS-21, Salyut will produce another Russian-Ukrainian turbofan engine - AI-436T12. In 2003, it was also planned to master the production of a number of units and assemblies of the D-27 propfan engine for the promising An-70 military transport, however, due to the position of the Russian Air Force on this aircraft, these works were suspended.
In addition, Salyut is repairing the AL-21F-3A engines it previously produced, which are used on Russian Su-24 front-line bombers of all modifications, and offers them the AL-21F-3M version upgraded during the repair with an increased thrust of 300 kgf. The repair of R15B-300 engines for MiG-25RB aircraft is also underway. The new turboprop engine TV-500S with a capacity of 630 hp is the own development of the enterprise's design bureau. for the SM-92T aircraft, which is planned to be handed over for bench tests next summer. It is also impossible not to recall that 20% of Salyut's income comes from work on civilian topics - primarily on industrial power plants created on the basis of obsolete aircraft engines.
However, no matter how wide the range of activities of MMPP Salyut is, there is no doubt that the basis of its production program is the manufacture, repair and modernization of engines of the AL-31F family. And it seems undeserved if the entire experience of the enterprise in this area is in demand only abroad. The most advanced aircraft of the Russian Air Force were traditionally equipped with Salyut engines, so maybe you should not ignore his proposals to further increase their combat capability?
Through modernization - to new engines
The market situation currently determines two main trends in the creation of aircraft engines:
- Phased modernization of existing engines and the creation of new ones based on existing modules and assemblies. This path can significantly reduce the time and cost of developing a new engine, as well as reduce technical risk, while maintaining the continuity of generations. By improving one engine, it is possible to obtain a sufficiently wide range of new engines and ensure a gradual transition to new generations without interrupting the design-manufacturing-sales cycle.
- Creation of completely new engines based on the accumulated scientific and technical reserve. Here, on the one hand, it is important to choose the right dimension and basic parameters of the engine in order to be able to create the widest possible range of engines on its basis in the future. On the other hand, a universal engine (or a gas generator) will lose in terms of technical characteristics to an engine specially designed for a particular application. Therefore, taking into account the high cost of developing a new engine, it is necessary to accurately find the line on which the very contradictory requirements for the gas turbine engine being created are most optimally combined.
Taking into account the limited possibilities of the state to finance the industry, FSUE MMPP Salyut developed a concept for the modernization of the serially produced AL-31F engine. This concept is based on the following main provisions:
Stages of modernization of the AL-31F engine
First step
Thrust R f =13300 kgf
Second phase
Thrust R f =14100 kgf
Third stage
Thrust R f =14600 kgf
- Modernization of the AL-31F is aimed at improving the traction and economic characteristics, reliability and service life through the phased introduction of progressive design and engineering and technological solutions into the serial design of the engine. The main trends in the development of modern aviation (weighting of aircraft (LA), increasing the range and altitude of flight, maneuverability and, at the same time, reducing the cost of production and operation) correspond to the use of a modernized engine based on a proven design and ensuring the fulfillment of the above tasks without stopping use existing LA fleet.
- The implementation of a complex of works (development, fine-tuning, serial delivery, operation and repair) under a single management allows solving problems arising at each stage in the shortest possible time. The unification at the enterprise under a single command of all work - advanced development, fine-tuning, production, serial support, maintenance and repair - makes FSUE "MMPP" Salyut "the only and fully responsible for the creation of a modernized engine. In this regard, the enterprise, in addition to previously For the existing technological services, whose role also increased, a design bureau for advanced developments (KBPR) was created.
Currently, the KBPR is staffed by qualified specialists and is working fruitfully. Equipping workplaces with modern computer technology, combined into a single information network, allows for complex automated design using the latest modeling methods and calculations of the engine as a whole, its individual components and parts. Modern computer technologies are used for thermal and strength calculations, calculations of gas dynamics and combustion, for three-dimensional modeling and preparation of design documentation. - The problem of creating scientific, technical and technological reserves at one enterprise with a high technological culture and certain financial capabilities can be solved at much lower costs on the part of the state. A negative example in this regard can be the history of the creation of one of the 5th generation engines, which was never completed due to the presence of these problems.
A modern engine is the most complex technical system in terms of design and technology. The design of the engine, technological processes that ensure its performance and high economic efficiency of production must meet world-class requirements. Therefore, of the modern technologies at Salyut, they choose those that are the most rational from a technical and economic point of view. Control programs for such equipment are developed by specialists of the enterprise and abroad. Along with the use of purchased programs, we are developing our own specialized processors for programming the processing of turbomachinery parts. Production at FSUE "MMPP "Salyut" is certified. The plant has the necessary Russian and international quality system certificates, as well as a license for the design of gas turbine engines. We intend to achieve consistent improvement in the main engine parameters through three stages of modernization. Before each of them, a certain amount of experimental design and design work, as well as a list of critical technologies that ensure the introduction of modernized units.It is assumed that the engines of each stage of modernization will be mass-produced, interchangeable with each other on aircraft and have improved performance compared to the previous ones. is achieved in the following way.
At the first stage of modernization (AL-31F-M1 engine):
- Efficiency with increased air flow is set
- the temperature of the gases T3 in front of the turbine increases by 25 o, the admissibility of which is confirmed by the necessary thermal calculations of the turbine
- the analog engine controller is replaced by a digital one
- a turbo starter with increased power by 15-20% and up to 3500 m launch altitude is used.
The engine thrust in this case increases by 800 kgf compared to 12500 kgf of the base AL-31F. The engine of the first stage of modernization has successfully passed bench and flight tests. Production is being prepared for its introduction into the series.
At the II stage of modernization (AL-31F-M2 engine), in addition to the previous ones:
- high-temperature modernized HPT and LPT turbines with spatial profiling blades are used. For engines AL-31F-M2, AL-31F-MZ, a casting version of the working blade (RL) of a multi-pass longitudinal-transverse cooling scheme with leading edge perforation has been developed. Here, the cooling air enters the area of the inlet edge, where it is partially blown onto the profile, and partially through horizontal (transverse) channels it is supplied to the area of the outlet edge, where it is ejected into the flow path. This RL design makes it possible to obtain a uniformly heated blade airfoil with minimal thermal stresses. The temperature of the gases increases by another 75 o
- a newly developed advanced combustion chamber (CC) with a double-walled flame tube is used. This ensures the organization of combustion with high combustion efficiency, reliable start-up of the combustor without the use of oxygen, reduced circumferential unevenness of the temperature field at the combustor outlet, increased combustor life with a significant reduction in cooling air consumption.
- an electronic-digital automatic control system with full responsibility and hydromechanical redundancy is installed.
Engine thrust increases to 14100 kgf.
Three stage compressor
low pressure AL-31F-M3
At the III stage of modernization (engine AL-31F-MZ) additionally, a new three-stage LPV with wide-chord blades of spatial profiling and an increased compression ratio of up to p k = 4.2, which allows to increase thrust up to 14600 kgf.
At any stage of modernization, an all-angle rotary nozzle can be installed on the engine, which is currently undergoing lengthy tests. The implementation of the three stages will ensure the creation of an engine with the characteristics of generation 4+. Tested in the process of modernization, new design and technological solutions with their further development can be taken as a basis for the development of advanced engines.
The AL-31F aircraft engine is installed on the Su-27 fighter and its modifications Su-27UB, Su-32FN, Su-34.
AL-31F is a dual-circuit, twin-shaft turbojet aircraft engine of a modular design with an afterburner and a supersonic adjustable nozzle.
Repair of aircraft engines AL-31F in the Aircraft Repair Network of the Air Force is carried out by FSUE "121 ARZ" of the Ministry of Defense of the Russian Federation (Kubinka).
Thrust in afterburner mode: 12500 kg.s.
Takeoff thrust: 7850 kg.s.
Specific fuel consumption in afterburner mode: 1.96 kg/hp
Specific fuel consumption in cruising mode: 0.666 kg/hp.h
Pressure boost ratio: 23.0
Maximum gas temperature in takeoff mode: 1660°K
Engine weight: 1530 kg
Dimensions:
– length: 4945 mm
– diameter: 910 mm
– height: 1240 mm
It was designed for
enterprises of KB them. Lyulki, located near the VDNKh metro station.
Huge work to optimize the turbine stages of this aircraft engine
performed by a group led by Professor MPEI, Doctor of Technical Sciences. V.D. Venidiktova (S.V. Granovsky (works at JV Alstom), A.M. Karelin. All three have two higher educations and graduated with honors from Bauman Moscow Higher Technical School. Baranova on the Aviamotornaya metro station.
And part of the work was done by Rybinsk Saturn.
The engine was tested in the village of Turaevo at the CIAM Research Center, not far from Lytkarino
under Moscow.
And already mass-produced at the Salyut plant, near the metro
Semenovskaya on Budenov Avenue and at the Ufa Industrial Association since 1981.
Directly at this plant in the center of Moscow
passed control tests.
Now Salut has built a stand in Kapotnya,
because the Muscovites did not want to hear the roar further.
As soon as the tests began, the computer of the SGA embassy immediately appeared and recorded the parameters of the aircraft engine.
Salyut sold these aircraft engines of a modified design to China, but even received losses due to the fact that for some reason the contract was concluded in US dollars.
KB Lyulka seems to have filed a lawsuit against Salut for not paying
or not all paid
for intellectual property of KB (payments for patents).
From each aircraft engine, he must pay deductions in KB.
And the dollar has depreciated a lot in a few years.
The Chinese are trying to copy the aircraft engine and arrange its export sale, like a Kalashnikov assault rifle, but so far they have not had time to do it.
That is, we can say that there are not literate economists on Salute.
Here is an example of how these aircraft engines helped Ethiopia in the war.
Russia donated or debited Ethiopia about $1 billion
debts.
Vedomosti. 01/13/2003. /Aleksey Nikolsky/.
Last year, Russia returned to the Ethiopian arms market, supplying one of the poorest countries in the world with seven Su-27 fighter jets worth over $100 million. "MiG".
Ethiopia thawed several prisoners back in 1998-1999. contracts and acquired last year through Rosoboronexport seven heavy Su-27 fighters from the Russian Air Force. This was reported to Vedomosti by an employee of the Russian Defense Ministry, whose words were confirmed by a source in one of the Russian aircraft manufacturing companies. According to the expert of the Center for Analysis of Strategies and Technologies Konstantin Makienko, the cost of one used Su-27 is about $15 million.
Ethiopia is considered one of the poorest countries in Africa. The Ethiopian population is often starving, and only international humanitarian assistance serves as salvation. Another famine, which began at the end of last year, threatens, according to the government of Ethiopia, more than 13 million inhabitants of this country. Ethiopia is often cited as an example of a country whose creditors must write off all debts - it is in such a difficult situation. This spring, renowned rock singer and underdeveloped countries debt relief activist Bono said in Addis Ababa: “It is simply inconceivable that Ethiopia, where 62% of adults cannot read and where one million children are orphans, pays $100 million a year to us ".
This country is ready to pay even more for weapons. According to the Military Balance directory, the country's military spending in 2000 amounted to $450 million with a GDP of $6.7 billion. However, Ethiopia's main enemy, Eritrea, with which it fought in 1998 and 2000. , spent $260 million on defense in 2000 with a GDP of $710 million. 1998 - 1999 from Russia under a contract worth almost $160 million, which also included artillery systems and ammunition. Eritrea then relied on six MiG-29s bought in Russia for $60 million.
In May 2000, the UN imposed an arms embargo on warring countries for a period of one year. After the end of the ban, both opponents, who were a single country until 1993, began to rearm. Thus, according to Marat Kenzhetaev, an expert at the Center for the Study of Disarmament Problems at the Moscow Institute of Physics and Technology, Eritrea ordered five more MiG-29s from RAC MiG in 2001 and, according to unconfirmed reports, bought several Su-27s from the Ukrainian Air Force. Ethiopia also thawed a second $200 million contract concluded with Russia in 1999, which probably includes an additional seven Su-27s. According to Kenzhetaev, the source of funds to pay for the contracts is difficult to identify, but Ethiopia certainly paid Russia for the weapons in foreign currency.
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