For the PD-35 high-power engine, the United Engine Corporation manufactures wide-chord fan blades from polymer composite materials using prepregs and 3D-weaving technology.
In order for the PD-35 engine to meet the requirements of the time for fuel efficiency and be attractive for installation on the Russian-Chinese wide-body airliner CR929 and, probably, on the IL-96-400M in a twin-engine version, the use of PCM as part of the fan blades is a necessary condition. The technology of manufacturing such blades is critical and belongs to the most promising areas of research. Without its development, it is impossible to achieve the target competitive characteristics of the PD-35.
In order to reduce the risks, the UEC decided to work out two technological directions: layer-by-layer laying out of a prepreg in a mold, which is a composite material-a semi-finished product, followed by polymerization in an autoclave-prepreg technology, as well as the formation of a three-dimensional woven reinforcing frame with subsequent impregnation under pressure in a mold and polymerization - 3D-weaving technology.
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| The technical process of manufacturing parts from PCM. |
| Source: aviation21.ru |
The new technology is being worked out in the dimension of the PD-14 engine, i.e., at the experimental stage, a blade with a size of 750 mm is used, as in the PD-14 design, and not 1250 mm, which will be used in the PD-35. Comparative tests of products manufactured by the two methods are planned for 2021.
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| The technical process of manufacturing parts from PCM. |
| Source: aviation21.ru |
The main developer of the PD-35 engine is JSC UEC-Aviadvigatel. In 2020, the company performed a large amount of work on the development of prepreg technology, including testing of a demonstration fan as part of the PD-14 engine. The creation of 3D-weaving technology is assigned to the developer of the low-pressure compressor of the PD – 35 engine-PJSC "UEC-Saturn". Currently, the 3D-weaving technology is used to produce structural-like elements and a set of working demonstration fan blades. In 2021, it is planned to conduct a set of comparative tests of the fan blades made of PCM, manufactured using both technologies.
"In 2021, it is planned to issue working design documentation for the fan blade in the dimension of the PD-35 engine, taking into account the experience gained. The technological preparation of production has already started - these are devices, molds, special cutting tools, etc.In 2022, the first samples of the fan blades should be received. When working out the two technologies, only domestic composite materials are used, " the press service of the United Engine Corporation noted.
The start of serial production and production volumes are inextricably linked with the forecasts for the implementation of the PD-35 project, and it is also possible to use this technology on an updated version of the PD-14 engine. The organization of manufacturing of PCM parts in the interests of third-party customers is not excluded.
