M.A.T.I

Participation of MATI scientists in Federal Aviation Engines Program

Thursday, December 29, 2011 0 comments

Cooperation with ”Salute” aviation
engine manufacturing enterprise

EVOLUTION OF THE AVIATION GAS TURBINE ENGINES

Generation	Type	Years of production	Gas temperature	Engine thrust, kg	Specific weight Engine weight thrust
I II III IV V	RD-45 AL-7 AL-21 AL-31 AL-41	1940-50 1950-60 1960-70 1980-2000 after 2000	1000 1250 1400 1650 1850	2270 9600 11300 12500	0.35-0.6 0.18-0.22 0.14-0.18 0.12 0.1-0.08

AL-31F - turbo-jet bypass engine with afterburning
chamber and upside positioning of the engine control units

Materials applied in production of aviation engines

Materials	Engine generation
Materials	II	III	IV
High-temperature alloys and steel	28%	41%	58%
Stainless steel	26%	12%	12.6%
Titanium alloys	5.5%	11.5%	31%
Aluminum alloys	7.3%	1.8%	0.28%

AL-31FP
turbo-jet bypass engine with afterburning chamber
and rotary jet nozzle

Technical parameters:
Diameter (entry) – 905 mm
Length- 4990 mm
Maximum thrust – 12500 kg
Mass – 1570 kg

The engine possess unique ability to function at wide-range altitudes and flight speed, stable functioning at the afterburning mode and deep pumpage, effective functioning at steep spin and inverted spin. The engine provides unique maneuverability for the aircraft

EVOLUTION OF AL-31F TURBO-JET ENGINE

EVOLUTION OF JET ENGINES

Generation	VI 1975 – 85	V 1995-2000	VI 2005-2010
Specific weight	0.125	0.1	0.05-0.08
Efficiency at afterburning	100%	115%	120 - 140%
Lifetime	1	1.5 - 2	Equal to the plane lifetime

Tendency in temperature increase in gas turbine engine

INVESTIGATION OF THE TEMPERATURE GRADIENT EFFECT
ON STRUCTURE OF THE HEAT-RESISTANT ALLOYS


The effect of the temperature gradient (G) at the interface of crystallization on dimensions of liquid-solid zone (λ)

A		B
The effect of temperature gradient at the interface of crystallization on microstructure of the heat-resistant alloy A – industrial technology at G = 30 °C/cm; λ = 350 μm B – developed technology at G = 200 °C/cm; λ = 160 μm

Increase of the temperature gradient at the interface of crystallization provides:

Decrease of liquid-solid zone dimensions, where dendrite structure is being created

Formation of homogeneous fine dendrite structure with low porosity

Application of the existing equipment

MICROSTRUCTURE AND FATIGUE CHARACTERISTICS OF THE
ENGINE BLADES (AL-31F ENGINE, 1st STAGE) MANUFACTURED BY
CASTING WITH HIGH GRADIENT CONTROLLED CRYSTALLIZATION

General view of the 1st stage blades manufactured by the method of high gradient controlled crystallization.

Behavior of high-temperature alloy mono-crystal under fatigue testing.

Microstructure of blade feather (a – transverse direction, b – longitudinal direction) and blade locking piece (c – transverse direction, d – longitudinal direction) of gas-turbine engine blade manufactured by the method of high gradient controlled crystallization, x 100. This method allows to increase the alloy strength on 10-15% and fatigue characteristics on 20-30%.

MODIFIED VACUUM INSTALLATION FOR CONTROLLED
CRYSTALLIZATION

Installation is designed for manufacturing mono-crystal casting articles (<= 200 mm) of complicated shape by the method of controlled crystallization.

Technical characteristics:
Power Working media Temperature of article heating Temperature of crystallization Velocity of crystallization Productivity	320kW Vacuum 1500°C 700°C 1-20 mm/min 10-12 smeltings/day

APPLICATION AND EFFICIENCY OF ADVANCED TECHOLOGIES FOR
GAS TURBINE BLADE COATINGS

1. Increasing of coating exploitation temperature, C:

Standard
Developed

2. Increasing of coating resource under high temperature oxidation:

Diffusive
Condensation
Condensation- Diffusive

950 C – 15000 hours
1100 C – 500-700 hours
1150-1200 C – 1500 hours

3. Efficiency of advanced technologies: Increasing of resource in compare with traditional aluminizing:

Diffusive
Condensation
Condensation - Diffusive

1.5-2
2-5
5-7

4. Application of advanced technologies in AL-31F, D 436T engines manufacturing


General view of turbine blades of various engines with traditional aluminizing on the inner and outer surfaces	Nozzle blades and turbine blades with protective heat-resistant coatings

ION NITRATION OF COG - WHEELS

Installation “SALUT-60”

Technical characteristics:
1. Number of working chambers 2. Working temperatures, C 3. Working pressure, Pa 4. Power, kW 5. Maximum voltage, V	2 400-800 13-1330 70 1000

Kinetics of nitration layer forming

Hardness of the core

Treatment parameters: 530 OC, 36 hours, Pressure=3-20 GPa, gas media 95% N2 + 5% H2

Structure of nitration layer

Main advantages

Low layer fragility
Low and stable thermal deformations
Low surface asperity
Double time decreasing of the process
Ecological safety
Increasing of the article exploitation characteristics

COMPARISON OF THE ION AND GAS NITRATION

EXPLOITATION PARAMETERS

Participation of MATI scientists in Federal Space Projects

0 comments

Cooperation with Khrunitchev
Space Center

Participation of MATI
scientists in Federal Space
Projects

Cooperation MATI with Khrunitchev
Space Center

Heavy class launch vehicle “Proton”

“Angara” family launch vehicles

Light class launch vehicle “Rockot”

Participation in Construction of the International Space Station

Unified Satellite Platform:
development of the small satellites family

Small Satellites

In 2001 Chrunitchev Space Center completed development of the satellite for space communication “Dialog”. Satellite has been developed on the basis of unified platform “Yakhta” . Estimated life-time – 10 years. Launch mass - 470–500 kg.

Accelerating Blocks

Chrunitchev Space Center is now actively working on development of 3 types accelerating blocks:
“Breeze KM”, “Breeze M” – both using long-term stored fuel and oxygen-hydrogen block.

“Breeze KM” block was developed for the light class launch vehicle “Rockot”.
“Breeze M” block was developed for new family of heavy class launchers “Proton – M” and “Angara”.