ZAPOROZHYE MACHINE-BUILDING DESIGN BUREAU PROGRESS STATE
ENTERPRISE NAMED AFTER ACADEMICIAN A.G. IVCHENKO
(SE IVCHENKO-PROGRESS)
Zaporozhye Machine-Building Design Bureau Progress State Enterprise named after Academician A.G. Ivchenko contributed much to the development of aviation industry. This is the Company, which for over 65 years has been involved in design of engines to power aircraft and helicopters of various types, and also drivers and special equipment of industrial application. For this period of time more than 80000 aviation piston and gas turbine engines, turbine starters and drivers of industrial application have been produced by engine manufacturers. The aero engines designed by SE Ivchenko-Progress power 54 types of A/C in 122 countries of the world. Total operating time of GTEs exceeds 300 million hours. The company is a part of the Ministry of Industrial Policy of Ukraine.
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HISTORY OF SE IVCHENKO-PROGRESS FOUNDATION
On May 5, 1945, under the People’s Commissar of Aviation Industry A. I. Shakhurin’s order No. 193 an experimental design bureau (OKБ) was established at OKБ-478 plant to design new and update aero engines of medium and low powers designed earlier for civil aviation. A regular designer Alexander Georgiyevich Ivchenko was appointed to be a Chief of the OKБ (Experimental Design Bureau) who later on (in 1963) became a Designer General of the Enterprise. The backbone of the new design bureau comprised the experienced specialists of the engine-manufacturing plant, which had passed a splendid school of design and development of aero engines ranged from М-11 to М-88B and Ash-82FN. In 1966 the enterprise was renamed to Progress Zaporozhye Machine-Building Design Bureau (ZMDB). Since 1994 the enterprise was named after Academician A.G. Ivchenko, and since 2004 - SE Ivchenko-Progress
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Outstanding designers who headed Zaporozhye Machine-Building Design Bureau Progress named after Academician A.G. Ivchenko :
• 1945 – 1968 – Alexander Gheorghievich Ivchenko;
• 1968 – 1989 – Vladimir Alexeyevich Lotarev;
• 1989 – 2010 - Fyodor Mikhailovich Muravchenko.
• since 2010 – Igor Fyodorovich Kravchenko
By 1946 the M-26GR engine (geared to power helicopters) with a power of 500 hp was designed at the Experimental Design Bureau. It was the first in the world air-cooled piston engine designed specifically for helicopters. The engine was designated as АI-26GR (“AI” means Alexander Ivchenko). The AI-26GR prototype engine and its updated versions: AI-26GRF and AI-26GRFL rated at 550hp and 575hp, accordingly, were installed on I.P. Bratukhin G-4, B-5, B-10, B-11 and A.S. Yakovlev Yak-100 helicopters. 30 prototype helicopters and 250 units of AI-26 GR/GRF engines were produced in total.
Most of the first prototype and production helicopters in the USSR were powered by piston engines designed by Zaporozhye OKБ
Since 1947 the experimental works on the development of 80 hp AI-10 light engine, an air-cooled 5-cylinder star rated at 80hp for Yak-20 training and sporting aircraft were started. 2 prototype aircraft and 9 motors were produced.
In 1948 the AI-4G engine rated at 55 hp was designed to power ship-based Ka-10 observation and liaison helicopters. 15 helicopters and 35 engines were manufactured.
In 1948, a unique AI-14 engine was also developed. Its aircraft version, AI-14R , a geared nine-cylinder air-cooled radial engine with supercharger rated at 265 hp was installed in a number of Yak-12 and Yak-18 airplane versions. These airplanes were both of training and combat application. 12000 units of airplanes were serially produced in the USSR, Poland and China, nearly 8500 units of them were powered by AI-14 engines. Over 12500 units of various versions of AI-14R were produced in these countries in total. This engine was also installed in STOL An-14 Bee, 327 units have been serially produced. Up to date, the engines of the AI-14 family, designated as M-14, power thousands of A.S. Yakovlev and P.O. Sukhoy light trainers, aerobatics, executive and agricultural airplanes operated in many countries of the world.
Kamov ship-based multipurpose Ka-15 and Ka-18 helicopters were powered by a helicopter engine version, AI-14V, rated at a power ranged from 255 to 280 hp. Totally, 465 helicopters and 1200 engines were manufactured.
In 1948 a seven-cylinder air-cooled radial engine, AI-12, with a power of 175 hp was also designed as based on AI-10 and AI-14 motors. The engine has undergone flight tests as installed in Yak-18M and Po-2 airplanes. A prototype batch of 4 engines was manufactured.
Cooperation of our company was especially successful with the M.L. Mill’s Design Bureau. Within a short period of time Mi-1 helicopter powered by AI-26V engine rated at 575 hp was designed and tested. The helicopter, designed in 1953, had more than ten modified versions both of civil and combat application. Its production was developed in two countries, the USSR and Poland, and totally 2691 units were manufactured. AI-26V engines, designated in Poland as Lit-3, were manufactured in total of 4000 units.
AI-26В |
Mi-1 |
Since 1953 the ОКБ has started the works on the development of gas turbine engines. The first line of the development was designing a powerful turbine starter, TS-12, for the NK-12 turboprop engine, a product of the state experimental plant No. 276 headed by N.D. Kuznetsov. These engines powered passenger Tu-114 and military An-22, Tu-95, Tu-126, Тu-142 aircraft. Totally 2500 units of TC-12F turbine starters were manufactured.
To supply compressed air for starting АI-14V and АI-26V piston engines installed on Ка-15, Ка-18 and Мi-1 helicopters a starting АI-2МК piston engine was designed in 1957. Over 5000 units were produced.
To gain an experience in design and development of gas turbine engines the TV-2F engine and technical documents to it were delivered by N.D. Kuznetsov’s DB. In 1954 our company developed a modified version of this engine, designated as TV-2T, with a maximum power of 6250ehp for An-8 (P) prototype transport aircraft. A development batch of 7 engines was manufactured.
In 1955 another modified engine version, designated as TV-2VK, was developed at our company and featured a maximum power of 5900 ehp and a specific reduction gear to drive pusher and tractor propellers of the world’s largest N.I. Kamov’s Ka-22 rotorcraft. The world’s records of flight speed and altitude were established. The engines were installed on the first unit of the Ka-22.
In 1957 the AI-7 engine with a maximum thrust of 60kgf was designed for the experimental V-7 (Mi-7) helicopter. Two engines were installed on the ends of a two-bladed propeller, which was started by a jet thrust. In 1959 the works on the AI-7 engine development were stopped for the V-7 helicopter program failed. A single prototype helicopter and 11 engines were manufactured.
In 1957 a single-shaft turboprop engine, AI-20, one of the world’s first GTEs with a long service life passed successfully the state tests. This was an engine of simple design, maintainable and inexpensive in production, with a high operational reliability. For many years its modified versions: AI-20A (of four series), AI-20D (of five series), AI-20K, AI-20M ranged from 4000 to 5250 ehp were operated successfully as installed in the passenger airplanes An-10, Il-18, and also in AF’s airplanes An-8, Il-20, Il-22. Today they power An-12, Аn-32, Be-12 and Il-38 aircraft. In the course of their operation tbo of 8000 h and assigned service life of 22000 h were achieved with AI-20M engine. About 14000 units of AI-20 engines of all versions were manufactured.
AI-20 |
In 1958 a turboprop engine, AI-24, rated at 2550 ehp was developed as based on the experience gained in designing the AI-20 turboprop engine and on advanced method of simulation. The engine modified versions power passenger An-24 aircraft and Аn-26, Аn-30 special-purpose airplanes. 2735 aircraft and 11 750 units of AI-24 engines of various versions were manufactured in total. In 1960 11 units of AI-24V turboshaft engines were manufactured for the first two V-8 (Мi-8) prototype helicopters. Later on, the works on AI-24V were stopped, because the TV2-117 engine was selected for Mi-8.
Starting from the 1960s the OKB have been involved in the activities on the development of bypass GTEs. In 1965 the AI-25 turbofan engine rated at 1500 kgf was designed to power Yak-40 aircraft, it was manufactured in a series of 1011 units. It was also operated as installed in M-15 agricultural airplane (Poland), 138 airplanes were produced, 6325 engines were in series production.
AI-25 |
Yak-40 |
In 1973 for the L-39 trainer produced in Czech Republic a modified version of AI-25TL engine with a thrust of 1720 kgf was designed. The engine was developed on the basis of the AI-25 turbofan engine having an extended exhaust pipe, HPT cooled blades and oil system providing operation of bearings under conditions of inverted flight. More than 5100 engines were produced. At present, about 2650 units of AI-25TL engines are in service in 37 countries of the world, and they are both of training and combat applications. Totally 2868 units of L-39 airplane were produced. The AI-25 engine modified version, AI-25TLK, powers JL-8 trainer (China), there are nearly 300 engines in operation, another modified version, AI-25TL 300.11, is installed on UAVs.
In the 1960s for supplying compressed air to start propulsion engines, for air conditioning and driving generators a family of small auxiliary power units (APU) both for civil and combat aviation was developed. These were AI-8, AI-9, AI-9V APUs for An-8, An-10, Be-12, M-15, Yak-40 airplanes and for majority of Kamov helicopters Ka-27, 27, -29, -31, -32, -50, -52, -60, and Mill helicopters Mi-6, -8(17), -10, -14, -24(35), -26, -28. Nearly 9900 aircraft equipped with APUs of the types, and 13000 starter engines were produced in total. Over 7000 APUs are in operation now.
In 1971 the first in the USSR high-bypass turbojet engine, D-36, featuring a maximum thrust of 6500 kgf to power a new Yak-42 passenger aircraft was designed. For the first time a three-shaft configuration with a wide use of titanium alloys and an advanced design, engineering and metallurgical novelties were introduced in the engine of such class. It was the first time in domestic engine-manufacturing industry when the engine had a modular design. The next improved versions of this engine are successfully operated on combat transports and multipurpose airplanes An-72, An-74, and also An-74TK-300 passenger aircraft. Up to now, about 1700 engines have been manufactured, and today, over 700 engines are in operation.
D-136 |
Mi-26 |
In the mid-1970s the D-136 turboshaft engine rated at 11400 hp was designed on the basis of the D-36.to power a combat transport helicopter Mi-26 with the world’s highest cargo-lifting capacity. Up to now, 945 engines have been manufactured, and 400 units are currently in operation.
In the frameworks of a military-technical cooperation of the countries-members of the CMEA (Council for Mutual Economic Aid) the DV-2 turbofan engine featuring a thrust of 2200 kgf was designed in 1984 to power L-59 trainer of Czech production. 65 aircraft have been produced. Starting from 1991 the engine was under production in small series of 70 units in Slovak Republic, it also powered prototype trainers: Yak-130 (Russian Federation) and L-15 (China).
In the first half of the 1980s the main efforts of the company were forwarded to the development of ultra-fan engine to power An-124 Ruslan strategic military transport airplane. A powerful high fuel-effective engine, D-18T, was developed as rated at 23430 kgf. It was also installed in An-225 Mriya, the airplane with the world’s highest cargo-lifting capacity. In total, 52 airplanes and 251 engines were manufactured. 188 units of D-18T engines are currently in operation.
The first domestic and the first in the world three-shaft prototype demonstrator, D-236T, with a maximum power of 9450 ehp was designed, and in 1985 it was tested. The engine was intended for solving the problems related to the development of an engine featuring a propfan configuration. Two units were produced.
INDUSTRIAL SECTOR IN SE IVCHENKO-PROGRESS HISTORY
Druzhba power saw
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An individual line of the company’s activities is the development of drivers for industrial application. The company has gained a great experience in this sphere of national industry. The history of activities in industrial field runs back to the 1950s.
The following piston engines were among the first ones designed by the company: the AI-2 for a world’s well-known Druzhba power saw, over 3million units were manufactured, AI-14PS for Sever-2, Ka-30 snowplanes, and Raduga hovercraft, nearly 450 units were produced. In addition, a Sich family of racing engines for motor-boating was designed.
From the early sixties begins the era of application of gas turbine drivers (GTDs) in the national industry. On the basis of AI-20 and AI-24 aero engines the families of drivers installed on the “SM-6” ekranoplan (a prototype of the Caspian Monster vessel), Burevestnik and Tayfun hydrofoils, and also on Sormovich hovercraft were designed. They were also used as drivers for the AI-24PGTE and PAES-2500 mobile power stations, 2UVAG water heating unit, BTU-800 mobile gas turbine-pumping unit, power station of Sever-1 pipe-welding facility, and as a source of compressed air for TKADS-200M oxygen-nitrogen-producing station.
The AI-8 auxiliary power unit has found its application in starting of main gas turbine drivers of Kalmar, Omar, Kasatka, Murena hovercrafts, and hydrofoil carrier platform of the VNT-1 helicopter non-contacting gangway. And, in our days, many production vessels are still in operation.
In the early 1970s, at the request of the Ministry of Coal Industry of the USSR, on the basis of the AI-8 the GIG-4 inert gas generator of high capacity and self-containment was designed that allowed to suppress underground fires and methane explosions faster. This unit is widely used in many domestic coalmines to perform rescue operations, and also in Poland and Czech Republic, where it is operated up to now.
A particular attention is paid to the works fulfilled at the request of the Ministry of Oil and Gas Industry. The drivers operated by using both diesel fuel and natural gas were designed for a family of Uralmach drilling units, and also the drivers intended to intensify oil production. 670 drivers were serially produced. A lot of oil and gas fields in Siberia were developed with using these drivers.
Gas turbine drivers for the PEM-1 search-and-rescue cross-country vehicle and machines for thermal treatment of military equipment UTM, TMS-65M have been developed on the AI-25TL basis.
SE IVCHENKO-PROGRESS today
The sphere of SE IVCHENKO-PROGRESS activities covers design, manufacture, test, development, certification, putting into series production and overhaul of gas turbine engines both of aviation and industrial application. More than 60 certificates of Bureau Veritas, EASA, Central Civil Aviation Administration of China, IAC AR and GosAviaSluzhba of Ukraine confirm a type design conformity, quality, reliability and the right to design, manufacture, overhaul and upgrade the engines.
D-27 |
An-70 |
To meet the expected growth in demand for aeronautical products the company is involved in the development of a number of new aero engines of civil and military application. Especially, it is the first in the world turbopropfan engine, D-27, rated at a maximum power of 14000 ehp, which is currently under official flight testing as installed in medium-range military airlifter An 70. The extensive preparation works to put aircraft and engines into series production have been fulfilled now, as well as, the development of a modified version, designated as AI-127, with a power of 14500 hp, a family of ultra bypass turbojet engines (about 13), AI-727, with a thrust of 9000…11000 kgf, driven by a reduction gear of noiseless wide-span fan of new generation designed for An-148T-type transport airplanes.
ТВЗ-117ВМА-СBМ1 |
An-140 |
ТV3-117VМА-SBМ1 turboprop engines and АI9-3B auxiliary power unit have been developed for a new regional An-140 aircraft. The works on a further extension of service life and improvement of reliability are performed with these engines.
The new passenger aircraft, Tu-334, An-148, as well as, Be-200 amphibian are ascended to the sky by new-generation engines of the D-436 family rated at a thrust ranged from 6400 to 8200 kgf. The engine series production is executed in cooperation of Motor Sich, JSC (Ukraine) with FGUP Salut MMPP and UMPO JSC (Russian Federation). In November 2008 the D-436TP turbofan engine, the first in the post soviet countries, received an airworthiness approval from EASA on compliance with the western airworthiness standards, while ensuring to Be-200ChS amphibian entering the European market.
D-436 |
Tu-334 |
An-148 |
Be-200 |
Now, a family of AI-222 turbofan engines with a thrust ranging from 2200 to 4500 kgf (afterburning version) designed for powering modern combat training airplanes is under development. In 2009 the program was completed and the Report on the joint state flight tests of Russian Yak-130 combat trainer powered by AI-222-25 engines rated at 2500 kgf was signed.
АI-222-25 |
Yak-130 |
The AI-222-25 series production is executed in cooperation with Motor Sich, JSC and FSUE Salut MMPP. The development of the AI-222-25F rated at 4200 kgf with afterburning power is at a final phase. The works on the development of AI-222-40 turbofan engine with a thrust of 3500-4150 kgf based on the baseline engine core for powering commercial aircraft are carried out now. For new aircraft and helicopters a development of turboprop and turboshaft versions of the AI-8000 with a power of 7000-8000 hp is under studying.
АI-450 |
Mi-2М |
A small-size turboshaft engine, AI-450, rated at 465 hp is designed for powering Ka-226 helicopter. Experimental batch of engines was manufactured at Motor Sich, JSC. The AI-450MS auxiliary gas turbine engine to power a regional An-148 aircraft is based on the AI-450 engine core, and a modified version, AI-450M, with a rear shaft output (400 - 465 hp) for upgrading Mi-2M helicopter is under development today. It is undergoing bench testing, and a preparation of series production is in progress. In addition, an uprated version AI-450-2 (630-730 hp) to power helicopters of Ansat type, AI-450C (400-465hp) and AI-450C-2 (630-730 hp) turboprop engines are also developed for light airplanes of Yak-18, Yak-152, SM-92T “Finist Turbo”, EV-55 type, as well as, modified versions of turbofan engines AI-450BP (409 kgf) and AI-450-2BP (560 kgf) for light multipurpose airplanes and UAVs.
By using a great experience gained in the development of AI-222-25 , AI-222-25F and D-27 engines the AI-9500F with a thrust of 9.5 tons of force is under study for using as integrated in the power plants of light combat airplanes.
Requests for proposal on advanced engines, AI-40 (3500-4500hp), to power commercial airplanes are under development.
New materials, control systems, elements and components developed on the basis of new concepts and prospective technologies are under investigation now at the company. The developed and evaluated ideas, technologies and materials are introduced not only in the new advanced engines, but also while modifying the existing serially produced GTEs, that provide new possibilities and a quality improvement of aircraft performance.
For increasing a weight-lifting capability and efficiency of An-124-100 transport aircraft a modified version of D-18T series 4 engine with a maximum take-off thrust of 25830 kgf is developed. The new An-124-100M-150 aircraft will be able to carry cargo of up to 150 tons.
For upgrading the Czech AeroVodohody L-39 trainer an engine modified version, AI-25TLSh, was developed as based on the AI-25TL. A combat mode of increased maximum thrust up to 1850 kgf is introduced. Installation of the modified engine extends a service life to L-39 aircraft by 10-15 years. In December 2008, the engine installed in L-39 airplane has undergone the state flight tests. Today, the upgraded L-39 airplanes enter AF of Ukraine.
D-336 |
Gas Pumping Unit |
The company’s designer team is developing the gas turbine drivers of industrial application. This line of activities enumerates 21 types of engines with a power ranging from 0.5 to 25 MW. The gas turbine drivers (GTD) of the D-336 family, rated at a power ranged from 4 to 10MW, and the AI-2500 with a power of 2.5MW are operated as integrated in 135 units in use at more than 31 compressor and 3 power stations in Ukraine, Russia, Belarus, Azerbaijan, Turkmenistan, Uzbekistan, Bulgaria, Turkey and Iran. All GTDs in operation have Certificates of Compliance awarded by certification centers of Russian Federation and Ukraine.
АI-2500 |
Power Station AI-2500 |
GTDs of SE IVCHENKO-PROGRESS design, rated at 2.5 MW, are operated as a part of electric power generating installations in tens of countries of the world, and, today, their derivative, the AI-2500, is extensively used both in Ukraine and Russian Federation.
Our company has designed a free turbine module, MST-198, a self-contained unit integrated in the modular gas turbine power-generating installations rated at 20 MW. Now it is under operation in Belarus and Russian Federation.
AI-19GIG |
АI-19GIG-А |
The SE IVCHENKO-PROGRESS’s latest development, AI-19GIG inert gas generator, has been designed for suppressing and localizing fires in tunnels, cable wells and in closed and semi-closed rooms of any type. A batch of the units has been delivered to South Korea, where their consumer’s characteristics acquired a high assessment. The next units of the AI-19GIG unit mounted on a truck chassis are manufactured.
R&D activities are carried out at the company on the development of a gas-pumping unit of a modular-container design, AI-45, rated at a power ranged from 0.5 to 1MW, a gas turbine driver AI-12N with 12MW of power and combustion chamber module for a 65 MW power station.
The company’s staff is an active participant in such international programs as: a program of development of light passenger aircraft of the Consortium of “Integrated Cesar Project (Cost Effective Small AiRcraft”) (with headquarters in Brussels, Belgium), EV-55 administrative airplane (Czech Republic), L-15 advanced trainer (powered by engine with afterburner) (China). It also participates in a delivery of technical documents and organization of production of a regional An-140 aircraft with engine in I.R.I.
The company offers to its Customers the services on mounting and maintenance of the gas turbine drivers, and also a personnel training at sites.
The company’s specialists perform the analysis of peculiarities of a driver operation at a particular compressor station, interactions between the stationary systems and GTD systems, make corrections in algorithms of the GTD control and adjustment, and also perform a personnel training in fast troubleshooting and elimination of abnormal situations occurred while operating. Similar procedures ensure a continuous operation and permit to improve consumer’s characteristics of GTDs.
A powerful intellectual, production and scientific-and-research facility of SE IVCHENKO-PROGRESS allows us to design gas turbine engines within a wide range of thrusts and powers.
The designer team and production section of the company work with using latest technologies. Today, SE IVCHENKO-PROGRESS possesses advanced technologies of designing and production. High-effective CAD/CAM designing and 3D calculations carried out on modern computer equipment, turbine single-crystal blades with a high-effective cooling system, compressor high-loaded stages manufactured by using a blisk technology (a disk integral with rotor blades), high-strength powder and granular alloys, composite materials and other advanced technical solutions are used today at our company for the development of new engines with high operating features.
The experimental and research facility of the company is one of the most powerful in Europe. It numbers 17 test benches and 78 rigs used for solving various problems related to the tests of engines, their per-component development, researches carried out for certification and further improvement of the design, reliability and fuel-effectiveness of the engines, etc.
SE IVCHENKO-PROGRESS carries out a common technical and marketing policy together with the Ukrainian and Russian manufacturers of gas turbine equipment. At present, the company has over 500 business partners, among which the majority are aviation enterprises of Russian Federation and Ukraine.
The gas turbine engines manufactured according to the SE IVCHENKO-PROGRESS documentation are successfully operated by numerous airlines in the world. The company maintains close interrelations with many of them, while offering services on overhauling the engines and ensuring the engine operation on technical condition. The company has a reputation of a serious and reliable partner among such airlines as Volga-Dnieper, Antonov Airlines, Anymex, Polyot and plus nearly 50 operators of the world.
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Today, the company looks with confidence in the future, it has everything to be one of the world’s leaders in the development of modern, reliable, ecologically friendly engines. This is ensured by its own designing school, its team of highly skilled specialists, splendid resource base, and, certainly, its honest, mutually beneficial relations with partners and users.
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See a detailed information about activities of SE Ivchenko-Progress, engine- designing company (with illustrations) on web www.ivchenko-progress.com
See a detailed information about activities of Motor Sich, JSC, engine- producing company (with illustrations) on web www.motorsich.com
© SE Ivchenko-Progress, 2004-2007
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