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PROJECTS
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TURKISH UTILITY HELICOPTER PROGRAM (TUHP)
18 : 14

Turkish Utility Helicopter Program has been initiated as per 05.12.2007 dated Defence Industries Executive Committee’s decision, in order to meet a total of 109 units of helicopter needs of 6 Turkish end users which consists of the Turkish Land Forces, Air Forces Command , Gendarmerie General Command, Directorate General of National Police, Directorate General of Forestry (DGF) and the Special Forces Command. For these 109 helicopters, 218 install and a minimum of 18 spare engines will be needed, which amount to 236 units of the T700-TEI-701D turboshaft engine, which will be in identical configuration with General Electric Aviation’s T700-GE-701D turboshaft engine model.

TUHP agreement has been signed between TAI and TEI as of 21.02.2014, with the participation of the Undersecretariat of Defence Industries (SSM) officials in Ankara. Within the Program, TAI will be the main contractor and TEI will be the subcontractor in charge of the licensed engine production.

TEI’s Role within the scope of the Utility Helicopter Program:

In the program, under GE Aviation license, TEI will be responsible for the production of 236 units of T700-TEI-701D turboshaft engine models, where TEI will manufacture over 60 piece parts (including subparts) and assemblies which correspond to over 50% of the entire engine, perform the engine assembly and testing, qualify the engine,  manage the engine configuration, and provide Integrated Logistics Support (ILS) services.  For the first time, hot section parts with high replacement rates over the life-time of the engine, such as the Combustion Liner, will be manufactured by TEI in Turkey.  In terms of after sales support, TEI will have the right to overhaul Turkish end-users’ entire T700 family of turboshaft engines with utilizing locally produced parts. At the same time, TEI will have the option to perform Depot Level Maintenance of T700 engines of licensed countries over a wide geographical range. With this program, TEI aims to provide optimal benefit to all of its stake holders through competitive pricing.

Program Duration:

Upon approval of the U.S. Government export  licenses, TEI will deliver the initial engines  27 months after the start of the program calendar  (September 2017), and the first and second T70 Helicopters will be delivered on the 55th (DGF configuration) and the 57th months (Common Base Line configuration) in January and March 2020. TEI’s activities within the Utility Helicopter Program will remain in effect starting from the delivery of the first T700-TEI-701D engine until the minimum 30 year operational life time of  last delivered (March 2028) T70i helicopter.

First time achievements within the Program:

  • Various mission needs of 6 different end-users will be consolidated and supplied through a common configuration.
  • GE Aviation’s T700-GE-701D turboshaft engine will be produced in Turkey under the T700-TEI-701D engine name plate, and it will be possible to export these engines abroad.

 

T700-TEI-701D Engine

T700-TEI-701D turboshaft engine, is the latest generation of T700 engine family, which is a front drive, turboshaft engine featuring an integral inlet particle separator; a  single-spool gas generator section consisting of a five-stage axial, single-stage centrifugal flow compressor, a through flow annular combustion chamber, a two-stage axial flow gas generator turbine; and a free two-stage axial flow power turbine. Rated at 2,000 shaft horsepower (shp), the T700-TEI-701D features improved hot-section components that provide twice the hot-section durability and 5 percent more power than the current T700-GE-701C model engine.

General Electric T700 Family of Engines Overview

The leader in its class, the T700 engine family powers military rotorcraft throughout the world. Ruggedness, safety and the ability to operate reliably under adverse environmental conditions while requiring minimal maintenance is the foundation of the T700 military engine family design. Since its introduction, the T700 engine family has amassed more than 60 million engine flight hours, powering over 20 types of rotary and fixed-wing aircraft for close to 125+ customers in 50+ countries.

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A400M TRANSPORT AIRCRAFT – TP400 ENGINE PROGRAM
18 : 13

Design, development and manufacturing activities of TP400-D6 engine are conducted by the Europrop International (EPI) Consortium consisting of MTU Aero Engines, Sencma, Rolls-Royce and ITP. At this project, TEI takes place as a risk and revenue partner with ITP.

 

First fligt of the engine with A400M aircraft was perfomed in Sevilli city of Spain at the end of 2009 and the engine was put into service at the end of 2013.

 

The work packages design, development, prototype production, assembly, testing, mass production and after sales support’s responsibility belongs to TEI:

 

  • Front Bearing Structure Module
  • Propeller Gearbox Supporting Bars
  • Primary Exhaust Nozzle
  • Exhaust Cone
  • Special to Project Test Equipment – SPTE

 

Engine Specifications

 

Engine Type
:
Turboprop
 
Engine Power
:
:About 11,000 shp (sea level)
 
Power Ratio  
:
25
 
Weight 
:
About 1,900 kg (dry)
 
Length 
:
3,5 m
 
Diameter  
:
0,92 m
 
Compressor
:
5 intermediate-pressure stage, 6 high-pressure stage
 
Turbine
:
1 high-pressure stage, 1 intermediate-pressure stage, 3 low-pressure stag
 

 

General Features:

 

  • The strongest turboprop engine of West Europe
  • High growth potential
  • Low life cycle cost
  • Component technology based upon civil and military applications
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LEAP ENGINE PROGRAM
18 : 14

Compressor blisk parts of the LEAP engine will be manufactured by TEI upon the agreement executed by and between GE Aviation and TEI on September 26, 2013. Blisk parts at 5 different stages will be manufactured in accordance with the agreement, and 60 million dollar will be invested. It is anticipated that sales of 1.2 billion dollar will be achieved by 2035.

In addition to blisk agreement, TEI, which has proved its manufacturing and engineering capabilities upon completion of many "concurrent engineering" projects that it has launched together with GE and Snecma, has received manufacturing orders for more than 15 LEAP parts in line with itstarget; and such parts will constitute business volume of 170 million dollar based on the numbers of current engine firm orders for as of 2018-2019.

 

New Applications

 

Blisk and spool parts with high geometrical complexity, which are started to be used recently in the new generation engines, are new practices for aviation industry. TEI announced proudly that it was one of the known companies in respect of the significant aircraft engine manufacturing technology throughout the world, upon execution of such agreement with GE Aviation. New generation LEAP engine symbolizes an important step in the aircraft engine technology in terms of fuel efficiency and cost effectiveness as well as of environmental factors. The fact that the blisks, which are the vital parts of the LEAP engines, will be manufactured by TEI is in compliance with the targets of strengthening the local manufacturing, and creating an additional employment area, and increasing the export capacity and competitive capacity of Turkey in respect of aviation products on a global scale, which are all included in the 2023 vision of Turkey.  The biggest purpose of TEI in such project is to guarantee the business volume of more than 230 million dollar on annual basis through the LEAP engine, and to be the biggest supplier of LEAP engine part throughout the world.

 

The processes such as inertia welding, 5 axis airfoil milling, curved slot milling (CSM), electrochemical machining (ECM), Ultrapolish-airfoil surface quality enhancement, robotic surface treatment, etc., which require advanced technology, will be applied within the LEAP engine blisk project. The activities for determining the technical requirements of the equipment to be used during such processes, and process developments are in progress

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COUGAR MAKILA 1A1 ENGINES LOGISTIC SUPPORT PROJECT
18 : 28

TEI has been commissioned by the Undersecretariat for Defense Industries as the main contractor for 3000-hour or 15-year depot level maintenance of the Makila 1A1 engines available in the inventor of Turkish Armed Force as well as for unscheduled maintenance of engines and modules. Accordingly, an agreement for the Cougar Makila 1A1 engines Logistic Support Project was executed with the Undersecretariat for Defense Industries on December 26, 2011.  This is the first project which is performed out of Supply and Maintenance Centers and it set a model  for the future’s Depot-Level Maintenance services of Turkey.

 

Under the project, TEI has acquired the necessary capabilities to carry out depot-level maintenance, repair, modernization and refurbishment processes domestically for Makila 1A1 engines of the AS532 Cougar Helicopter with the cooperation of and in collaboration with the 1st Command of Air Supply and Maintenance Center.

 

Activities carried out by TEI under the Cougar Makila 1A1 Engines Logistic Support Project:

 

•             Engine Inlet Checks

•             Engine Inlet Tests

•             Engine Removal

•             Module Removal

•             Diagnosis

•             Accessory Repair / Testing for Air Supply and Maintenance Center

•             International Turbomeca Repairs

•             Part Orders

•             Module Assembly / Balance

•             Engine Assembly

•             Testing

•             Shipment

Engine Modules Maintained;

 

•             Module 1            Air Intake Casing

•             Module 2            Axial Compressor

•             Module 3            HP Gas Generator 

•             Module 4            Rear Bearing

•             Module 5            Power Turbine

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DEPOT LEVEL MAINTENANCE PROJECT FOR TF33 ENGINES
18 : 29

12,000 - 18,000 hour periodic Depot Level Maintenance and ad-hoc maintenance services for the TF33-PW-100A engines of NATO AWACS aircraft are performed by TEI and Air Supply and Maintenance Center in collaboration under the MG2012/TU contract executed by and between TEI and IAMCO, which will remain in effect until December 31, 2021. TEI has been authorized for providing maintenance and repair services for some engine parts and accessories besides the engine under this contract. As part of the project, scheduled/ unscheduled maintenance of more than 100 TF33 engines have been performed by TEI so far.

 

TEI was selected as the "Best Source of Repair" by NAMSA and IAMCO in 2004, 2008 and 2012 thanks to its superior services.

 

Activities carried out by AIT Management for TF33 Engines are,

•             Engine Inlet Checks

•             Engine Inlet Tests

•             Engine Removal

•             Diagnosis

•             Repairs for ASMC

•             Accessory Repair / Testing for ASMC

•             Engine Assembly

•             Testing

•             Shipment - Engine Shipments NATO

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TURBOSHAFT ENGINE DEVELOPMENT PROJECT
11 : 55

For several projects that have been recently launched by Turkey and are still underway including Original Light Utility Helicopter, ATAK Helicopter and Turkish Utility Helicopter, thrust systems are procured from foreign sources. The Turboshaft Engine Development Project (TEDP) aims to decrease this dependence on foreign sources while enabling domestic production of the engine systems, which constitute one of the most important components of these projects, and increasing the percentage of indigenous production in these projects. In this context,Turboshaft Engine Development Project has officially iniated on 07 February 2017.

The project will be carried out under the leadership of Undersecretariat for Defense Industries (UDI) Sub-Systems Department, under which design, development and testing infrastructure for as turbine engines will be generated in our country on one hand, and the 1400 shp original and national engine with the applicable type certificate will be developed by TEI in order to be integrated into the Original Helicopter, on the other hand.

Turboshaft Engine Development Project will be carried out for 8 years by a team of approximately 250 engineers all of whom are TEI employees serving at TEI's Engineering Offices in Eskisehir, Ankara and Istanbul.

Any future derivatives of the engine may be utilized to power the national platforms such as ATAK and HURKUS. Moreover; core technology of the engine will form the basis for the engine needed for "National Training/Fighter Aircraft - T/FX", and it will be possible to develop the national aircraft engine when needed, upon any necessary technological additions to the capabilities gained under Turboshaft Engine Development Project . 

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TJ35 TURBOJET ENGINE
18 : 58

TEI develops turbojet and turboprop engines to meet the gas turbine need of competitive, innovative, high-tech Unmanned Aerial Vehicles (UAV) which are anticipated to be released to the domestic market first and to the international market in the long-term. Accordingly, R&D studies continue at TEI since 2004. TJ35 turbojet engine have been developed as part of these studies.

 

TJ35 TURBOJET ENGINE

Increasing demand for unmanned aerial vehicles, and therefore development of projects in this direction in the military and civil aviation industries in Turkey have raised the needs regarding the thrust systems of aircraft. Accordingly, TJ35 turbojet engine development project was realized between 2004-2005 with the aim of technical capability development.

 

Main characteristics and technical specifications of the TJ35 engine:

  • Air and propane start
  • ECU with ground station data link

Max. Thrust (N)/(lbf)

178/40

Specific Fuel Consumption (kg/N.h)/(lb/lbf.h)

0.135/1.35

Max. Rotor Speed (RPM)

120,000

Dry Weight (kg)/(lb)

3.1/6.8

Length (mm)/(in)

250/9.8

Diameter (mm)/(in)

130/5.1

Time Between Overhaul (h)

25+

 

All values are based on ISA at sea level conditions.

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TJ90 TURBOJET DEVELOPMENT PROJECT
9 : 0

TEI develops turbojet and turboprop engines to meet the gas turbine need of competitive, innovative, high-tech Unmanned Aerial Vehicles (UAV) which are anticipated to be released to the domestic market first and to the international market in the long-term. Accordingly, R&D studies continue at TEI since 2004. TJ90 turbojet engine have been developed as part of these studies. Inspections and testing of these engines are carried out by means of electronic control units developed by using fully domestic facilities.

 

TJ90 TURBOJET ENGINE

In January 2011, we initiated studies to develop a turbojet engine that provides a higher thrust compared to the initially developed TJ35 engines. As part of the project carried out with the support of TEYDEB, a collaboration agreement was executed in March 2012 for use of the engine in TAI's platform "Simsek".

The initial flight test was performed on June 5, 2013 and the engine development tests are still in progress.

 

Main characteristics and technical specifications of the TJ90 engine:

  • Direct kerosene start
  • Electric start
  • EMI/EMC compliance
  • Resistance to catapult g-loads
  • ECU with ground station data link
  • Developed for military usage

 

Max. Thrust (N)/(lbf)

400/90

Specific Fuel Consumption (kg/N.h)/(lb/lbf.h)

0.15/1.5

Max. Rotor Speed (RPM)

100,000

Dry Weight (kg)/(lb)

3.6/7.9

Length (mm)/(in)

413/16.3

Diameter (mm)/(in)

153/6

Time Between Overhaul (h)

25+

 

All values are based on ISA at sea level conditions.

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TP38 TURBOPROP DEVELOPMENT PROJECT
16 : 54

TEI develops turbojet and turboprop engines to meet the gas turbine need of competitive, innovative, high-tech Unmanned Aerial Vehicles (UAV) which are anticipated to be released to the domestic market first and to the international market in the long-term. Accordingly, R&D studies continue at TEI since 2004. TP38 turboprop engine have been developed as part of these studies..

 

TP38 TURBOPROP ENGINE

 

The TP38 Turboprop Engine Development Project was launched in 2005, using TJ35 engines as core engines. The turboprop engine developed was also considered suitable for use in the Turna target drone platform developed by TAI and studies continued in this direction.

 

A collaboration protocol was executed by and between TAI and TEI for integration of the engine into the aircraft and performance of flight tests; and the flight tests were performed under this protocol.

 

The Turboprop Engine Development Project was granted with "Innovation and Technology Award" at the 8th Technology Awards Congress organized by TUBITAK, TTGV and TUSIAD in 2009.

 

Main characteristics and technical specifications of the TP38 engine:

  • Air and propane start
  • ECU with ground station data link
  • Available for puller and pusher platforms

 

Max. Power (kW)/(hp)

31/41.7

Specific Fuel Consumption (kg/kW.h)/(lb/hp.h)

0.66/1.09

Max. Core Speed (RPM)

120,000

Max. Propeller Speed (RPM)

7,000

Dry Weight (kg)/(lb)

11.5/25.3

Length (mm)/(in)

530/20.9

Diameter (mm)/(in)

280/11

Time Between Overhaul (h)

25+

 

All values are based on ISA at sea level conditions.

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DILEK
18 : 11

Titanium alloys are widely preferred in aviation applications due to their advantages such as high tensile strength/density and toughness values, good corrosion resistance and endurance at high temperatures.

 

Hot forming methods are used to manufacture structures with a complex geometry at desired mechanical features from the titanium alloys which are hard to process and shape due to their characteristic features. Superplastic forming is a hot forming method performed under special temperature and loading conditions.

 

The Dilek Project, backed up by the Undersecretariat for Defense Industries, is carried out by TAI and TEI in collaboration with the aim of developing superplastic forming process for titanium alloys which are used in both platform and engine applications in aviation industry, and as a result reducing dependence on foreign sources.

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YAKUT
18 : 11

Metal Powder Laser Melting (LAM) process is a method of additive manufacturing, which is regarded as the manufacturing technology of the future, and the YAKUT Project aims to introduce this method to the defense industry in our country for functional part manufacturing from nickel super alloys. In general, additive manufacturing technology is based on the principle of part manufacturing by solidifying molten string, powder or sheet metal material as successive layers. It is regarded as the new industrial revolution of our time because of the advantages it provides such as a high level of freedom in design, weight and cost reduction.

 

Backed up by the Undersecretariat for Defense Industries (UDI), the YAKUT Project aims at acquisition of the Metal Powder Laser Melting (LAM) process as well as the process modeling capability for manufacturing of functional parts that have advanced mechanical features and can operate under challenging conditions such as high pressure and temperature differences in aircraft engines. Accordingly, under the project, the combustor component of the TJ90 turbojet engines, which consists of 9 sub-components, will be manufactured from UNS N06625 nickel super alloy material in one piece by using additive manufacturing method in a way to meet the mechanical requirements.

 

Through  the know-how and experience to be gained with the YAKUT Project, it is aimed for TEI to become a main engine manufacturer that is capable of manufacturing parts by using additive manufacturing methods in its own engines in the long term.

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INCI
18 : 12

The precision casting method allows achievement of higher dimensional precision and better surface quality and reduction of costs in high-volume productions compared to other casting methods.

 

Backed by the Undersecretariat for Defense Industries, the INCI Project aims at acquisition of the manufacturing capability domestically for the titanium alloy parts needed in air platforms through precision casting method.

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OPERATIVE UAV ENGINE DEVELOPMENT PROJECT
18 : 13

The project, which is signed between TEI and Undersecretariat for Defense Industries (UDI) on December 27, 2012, contains developing a turbodiesel aviation engine with domestic facilities which has superior technical specifications, in accordance with the needs of MALE class unmanned air vehicles.

 

With the project, which is planned to be completed in 2018, Turkey will have an overqualified  national turbodiesel engine which can be used for MALE Class UAVs. The project is in the stage of protoype manufacaturing while the detail design studies continue along with certification processes

 

Airworthiness Certification based on EASA CS-E and Design Organization Capability Approval based on EASA Part 21 will be obtained for the Operative UAV Engine under development, which will be a first in Turkey.

 

Advantages of the Operative UAV Engine in comparison with the current MALE Class UAV Engines are listed below:

 

  • More Power,  Higher Power/Weight Ratio
  • Higher Power Capability at High Altitude
  • Less Fuel Consumption
  • More Compact Design
  • Airworthiness Certification Compatible Civil Aviation Standarts and Military Standards
  • Indigenous Engine Control System Software and Hardware (Open code, upgradeable)
  • Fast Technic and Logistic Support
  • Need-Based Power-boost potential

 

Technical specfications of the Operative UAV Engine:

Maximum Continuous Power: 
 :
170HP
 
Weight:
:
170 kg 
 
Specific Fuel Consumption
:
<210 gr/kWh 
 
Electricity Power Generation Capacity:
:
9 kW (2 x 4.5kW)
 
Critical Altitude
:
20.000 ft
 
Maximum Altitude
:
30.000 ft
 
Propeller Rotation Control
:
Variable pitch , Single lever control, hydromechanics
 
Gear Case
:
Impeller configuration
 
Engine Control
:
Redundant Electronic Engine Control System (FADEC)
 
Engine Control Software
:
Indigenous DO178-C DAL-C compatible
 
EGÜS Control Software:
:
Indigenous DO178-C DAL-C compatible
 
Fuel 
:
JP8, Jet A1, Diesel
 
Aircraft Interface 
:
Mechanical, Electronic and Signal interface compatible with MALE Class UAV 

 

 

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DIESEL ENGINE MODIFICATION PROJECT
19 : 24

This project is intended for modification of the commercial diesel engine planned for use in the Unmanned Aerial Vehicles (UAVs), so as to meet the needs of UAVs. The power supply and electricity generation of the engine at high altitude conditions are increased through the modifications, making it ready for use in UAVs.

 

Technical specifications of the Modificated Engine:

Maximum Continuous Power
:
155 hp
 
Weight
:
165 kg 
 
Fuel Consumption
:
<215 gr/kWh 
 
Electricity Power Generation Capacity
:
9 kW (2 x 4.5kW)
 
Critical Altitude
:
11.500 ft  
 
Maximum Altitude
:
30.000 ft
 
Propeller Rotation Control
:
Variable pitch , Single lever control, hydromechanics
 
Gear Case
:
Impreller configuration
 
Engine Control
:
Redundant electronic engine control system (FADEC)
 
Engine Control Software
:
 DO178-C DAL-C compatible
 
EGÜS Control Software
:
 DO178-C DAL-C compatible
 
Fuel
:
JP8, Jet A1, Diesel
 
Aircraft Interface
:
Mechanical, Electronic and Signal inrerface compatible with MALE Class UAV