TEI to Exhibit Unique Products Powering Up National Platforms at the Eurasia Air Show

TEI, Turkey’s leading engine and component manufacturer, is getting prepared to participate in the Eurasia Air Show which will be held under the auspices of the Presidency of the Republic of Turkey on 25-29 April 2018. During the 5-day Fair, TEI will exhibit the unique PD 170 turbodiesel engine to power national platforms, TS1400 turboshaft engine mockup, TJ90 turbojet engine, 5-stage blisk of the new generation LEAP engine and engine parts manufactured through the method of additive manufacturing

Issue 81

TEI, which increased its total domestic and foreign sales figure to $320 million in 2017 and obtained $268 million in total turnover from export sales, continues to grow on a global scale in civilian and military aviation engines and parts production with over 2,000 employees, 600 of which are engineers.

In 2017, TEI attained nearly 80% of its sales volume from the production of civil aviation engines and the remaining 20% from the production of military engine parts and modules, product development and AIT & MRO activities. Today, TEI has more than 800 different production parts in its portfolio.

The Biggest Supplier of LEAP Engines in the World 

While TEI assumes a major responsibility for the new generation LEAP engine, it is producing many critical parts of this new generation engine on its own which powers the new generation A320 Neo and Boeing 737 Max aircrafts, and is the world’s biggest engine part supplier of LEAP engines.

An agreement was signed between GE Aviation and TEI on 26 September 2013 for the manufacturing of compressor blisk parts of the LEAP engine at TEI facilities. Within this scope, 5-stage blisk parts of LEAP engine are being produced at TEI facilities, and TEI’s Advanced Manufacturing Technologies facility is one of the two facilities that is capable of manufacturing compressor blisk parts for this engine. 

This facility which will be TEI’s first digitally intelligent factory, incorporates features such as production planning based on real-time data, process optimization, real-time parts and parts motion monitoring system, intelligent systems based on warnings and prevention mechanisms, preventive maintenance depending on real machinery data and paperless manufacturing as well.

Today, approximately $2.2 billion of this finalized backlog is composed of the parts that will be manufactured until 2035 for the LEAP engine.

TEI’s Unique Engines to Power National Platforms

TEI has gained significant capability and know-how since its establishment through the investments made also for military aviation engine and part production and is assuming critical responsibilities in indigenous projects initiated by the Undersecretariat for Defense Industries (SSM) to power the national platforms such as TS 1400 Turbo Shaft Engine Development Project, Operative UAV Engine Development Project and National Turbojet Engine TJ90 Project.

At the engineering offices of TEI in Eskişehir, Ankara and Istanbul, a strong team consisting of 250 engineers specializing in Aerothermal Engineering, Structural Engineering, Product Engineering, as well as in Engine Prototype and Testing, Electrical / Electronic - Control and Embedded Systems disciplines was established for the Turbo Shaft Engine Development Project which was initiated for the integration of an indigenous engine developed with the domestic facilities with the T625 Multi-Role Helicopter and the contract of which was signed between SSM and TEI on 07 February 2017; substantial investments were made for the infrastructure.

The development program which is scheduled to last for a total of eight years as per the project model consists of 5 stages: development of the core engine, prototype engine stage, mature engine stage, certified engine stage and integrated engine stage. Following the successful completion of all stages, the developed 1400hp turboshaft engine is planned to be integrated to the T-625 Multirole Helicopter and certified.

With the achievements obtained during the development process, the gas turbine engine design and development infrastructures are aimed to be built in Turkey and the versions of the engine to be developed in the future are aimed to power other national platforms such as T129 “Atak” and Hürkuş. 

PD170 Engine to Power up the “Anka” UAV Platform and Potential for Other Platforms

The development contract was signed between SSM and TEI on 27 December 2012 within the scope of the Operational UAV Engine Development Project which was initiated to develop a unique turbodiesel engine that would be a solution for the requirement of “Anka” and similar class UAVs.  A decision was made to increase the engine power from 155hp to 165hp as a result of the negotiations between SSM, TEI and TAI regarding engine power, weight and fuel consumption which are the basic parameters of the engine, during the first phase of System Requirements Identification Phase that is the first phase of the project, with the aim to develop a unique UAV engine with superior features on a global scale.

During this period, a 170hp power engine target was set and the engine architecture was designed to support 210hp by taking into account the future requirement of “Anka” configurations.

The PD170, with its dual-stage turbocharging system and fuel consumption, has achieved significant performance values amongst its competitors. The PD170 engine achieves this result with its high in-cylinder pressure resistance, high fuel pressure, low friction losses and thermodynamic gains from dual-stage turbocharging. It is expected that the PD170, which also has a better power / weight ratio than most of its competitors, will be in the leading position on the global scale with its 210hp version.

TEI delivered one of the first prototypes to TAI on 14 November 2017 for the purpose of performing the ground tests and to be used for “Anka” integration. The design changes realized by TEI in the following period will be applied to the engine that is present at TAI together with the prototype engines, the tests of which are being conducted at TEI test systems.  The related studies will be conducted to prepare the engine for the first flight test. Within the scope of the project where the integration studies conducted by TAI are aimed to be completed in a short period of time, the first flight test is planned to be performed under limited conditions in the first half of 2018. Through this test, the verification of engine-aircraft integration will be achieved rather than a verification activity regarding the engine. In addition to validating flight data for verification of engine-platform integration, verification of altitude-conditioned tests performed on the ground by TEI will also be achieved.

Taking into consideration the needs of other possible platforms other than just for “Anka” has opened new doors for the PD170 engine. Thanks to the dual-stage special turbocharger system, the PD170 will be the first and only turbodiesel UAV engine in the world capable of operating at 40,000 ft. In the design process, considering the future needs, the main systems of the engine were designed to meet 210hp. With the improvements to be made in this regard, it will also be possible to increase the engine power to 210hp.

TJ90 Turbojet Engine Made its First Flight with High-Speed Target Drone “Şimşek”

TEI will also exhibit the national TJ90 turbojet engine designed and manufactured by TEI with features such as electric start, resistance to catapult loads, ground station data-linked engine control unit and which can provide 400N impulse at maximum speed (under sea level conditions). The TJ90 turbojet engine was integrated to Turkey’s first turbojet-powered, High-Speed Target Drone “Şimşek” in 2017 and made its first flight seamlessly at an altitude of nearly 10,000ft and a speed of 200 knots at the Sivrihisar military base region.

Wide Range of Parts are being Manufactured at Additive Manufacturing Technologies Center

TEI, which allocates a significant share to R&D investments from its own resources, has accelerated its infrastructure activities for additive manufacturing technologies thanks to the projects conducted with the support of the Undersecretariat for Defense Industries since 2013. In this context, particular importance was placed upon the creation of comprehensive know-how on the additive manufacturing process and related test work, training of qualified personnel, training and experimental work in order to increase their competence.

As a result of such studies, the necessary infrastructure for this technology was established in a short span of time. Within the scope of the YAKUT project, which was initiated with the support and funded by SSM in 2014, TEI has increased its know-how in the manufacturing of aviation engine components by using super alloys through method of metal additive manufacturing and has taken its place amongst the countries that implement this technology in the world. The combustion chamber, consisting of 9 sub-parts of the TJ90 engine, was successfully manufactured in one piece through the additive manufacturing process in such a manner to provide the desired mechanical and metallurgical features. At the end of 2017, again with the support of SSM, it initiated a project called ELEKTRON (Melting Process Development through Electron Beam). As a result of the investments, many parts were successfully manufactured for different engine components of various modules with this technology which provides great time savings in the prototype manufacturing processes carried out within the scope of National Engine Projects (TJ90, PD170, TMGP etc.).

In the upcoming period TEI aims to perform the necessary certification (NADCAP etc.) activities in accordance with customer requirements and international standards in order to utilize metal additive manufacturing technology to create value both in the national and international arena