Rostec Increases Engine Life of Tu-160 Aircraft

UEC-Kuznetsov, a subsidiary of Russia’s state-owned Rostec is using robotic equipment to increase service life of engines, including those that power Tu-160 strategic bombers.

UEC-Kuznetsov put into operation a robotic plasma spraying complex that automatically applies refractory and hardening coatings to engine parts, ensuring absolute repeatability and high quality.

“The new software-controlled equipment complies with modern environmental standards. The industrial robot will increase the service life of gas turbine engines of all types, including the NK-32 series 02, used on the Tu-160 strategic missile carriers,” the aviation cluster of the Rostec State Corporation said.

To increase the throughput of production, the robotic plant is equipped with two working areas. In one of them, specialized ceramic coatings are applied to small-sized parts - compressor blades of the first and second stages, turbine nozzle sections. This design allows to apply coatings sequentially on 12 products during one working cycle. In another working area, large-sized titanium ring blanks with a diameter of up to 1.5 meters are processed in a special retractable chamber.

“All the equipment that the new production facilities of UEC-Kuznetsov are equipped with is high-tech and productive. The robotic plasma spraying complex will process parts of the compressor and turbine of gas turbine engines not only for the enterprises of the United Engine Corporation - within the framework of import substitution programs, the equipment can be widely used in the interests of the domestic industry,” said Deputy General Director - Managing Director of PJSC UEC-Kuznetsov Alexey Sobolev.

At the moment, the robotic complex meets the needs of production, processing up to 100 ring parts monthly when working in two shifts. If necessary, the capacity of the equipment can be increased up to 300 units of large parts and up to 1000 parts of small dimensions.

The robotic plasma torch performs deposition using a current of up to 1000 amperes with the supply of gases (nitrogen and argon) and metal powder for deposition. The equipment applies coatings with a thickness of 0.1 mm to 3.5 mm. Modern control systems guarantee the stability of the work process in the conditions of round-the-clock operation of the complex. The area is equipped with the latest exhaust ventilation units with filters that prevent metal dust from entering the atmosphere, and the soundproof coating inside the cabin completely eliminates sound exposure to ensure a comfortable workflow and compliance with accepted technical standards. The complex is operated by two operators.