Turkish Engine Programs

[xxxKULxxx]

Tech. Minister said " TÜBİTAK will lead domestic automobile goal. "

 

[ANMDT]

From a legit source i received a new ;
Navy maintenance division had acquired parts of engine from MTU, possible for 3rd or 4th milgem and mounted it up by themselves .
Engine is going on durability tests and other procedure of tests in MTU's test facilitiy in turkey , Navy providing all expenses on engine.
What i want to know, is that a usual procedure navy does for acquistion of engines,or its something unusual? Since engine is mounted up from the basic screw to shafts inside.
Is it an effort to gain maintenance ability of new engines,or an effort to make a way through engine, or just a procedure for securitiy clearance?

 

[-SINAN-]

From a legit source i received a new ;
Navy maintenance division had acquired parts of engine from MTU, possible for 3rd or 4th milgem and mounted it up by themselves .
Engine is going on durability tests and other procedure of tests in MTU's test facilitiy in turkey , Navy providing all expenses on engine.
What i want to know, is that a usual procedure navy does for acquistion of engines,or its something unusual? Since engine is mounted up from the basic screw to shafts inside.
Is it an effort to gain maintenance ability of new engines,or an effort to make a way through engine, or just a procedure for securitiy clearance?

@Some1LikeU Your first question brother.

 

[kalu_miah]

Diesel engine manufacturers:
Diesel engines, Diesel motors - All industrial manufacturers - Videos

Altay tank engine from MTU:
Otokar orders engines for prototype Altays | TR Defence
Detail: MTU Online
Army Guide - MT 883 Ka-500, Diesel engine

Ukrainian tank engine:
KMDB - Tank Power Pack with 6TD-2 Engine
Ukraine to Deliver Advanced Tank Engines to Pakistan | ASIAN DEFENCE NEWS

 

[xxxKULxxx]

ASELSAN will produce electric engine...

More target fields of ASELSAN inside...

Yerli motor geliyor-Sabah - 07 Ekim 2014

 

[what]

Batteries are as important as the engines when it comes to electric cars.

 

[ANMDT]

Batteries are as important as the engines when it comes to electric cars.

Batteries are more important actually , and SSM is conducting projects for components to be use in batteries, in cooperation to universities.

 

[-------]

Electric engines are piss easy to manufacture, Vestel and some other company (forgotten name ) already have electric engines for cars..

 

[-SINAN-]

@xxxKULxxx and others.

Guys, a few days ago we discussed about making an indigenous jet engine. I want to show you how complex is the whole jet engine making process.

Mate, bolded red parts are our capabilities as far as i know. (feel free to correct me)

The Manufacturing
Process
Building and assembling the components of a jet engine takes about two years, after a design and testing period that can take up to five years for each model. The research and development phase is so protracted because the engines are so complex: a standard Boeing 747 engine, for example, contains almost 25,000 parts.

Building components — fan blade

• 1 In jet engine manufacture, the various parts are made individually as part of subassemblies; the subassemblies then come together to form the whole engine. One such part is the fan blade, situated at the front of the engine. Each fan blade consists of two blade skins produced by shaping molten titanium in a hot press. When removed, each blade skin is welded to a mate, with a hollow cavity in the center. To increase the strength of the final product, this cavity is filled with a titanium honeycomb.

Compressor disc

• 2 The disc, the solid core to which the blades of the compressor are attached, resembles a big, notched wheel. It must be extremely strong and free of even minute imperfections, as these could easily develop into fractures under the tremendous stress of engine operation. For a long time, the most popular way to manufacture the disc entailed machine-cutting a metal blank into a rough approximation of the desired shape, then heating and stamping it to precise specifications (in addition to rendering the metal malleable, heat also helps to fuse hairline cracks). Today, however, a more sophisticated method of producing discs is being used by more and more manufacturers. Called powder metallurgy, it consists of pouring molten metal onto a rapidly rotating turntable that breaks the metal into millions of microscopic droplets that are flung back up almost immediately
  
  
  
  Turbine blades are made by forming wax copies of the blades and then immersing the copies in a ceramic slurry bath. After each copy is heated to harden the ceramic and melt the wax, molten metal is poured into the hollow left by the melted wax.
  A jet engine works by sucking air into one end, compressing it, mixing it with fuel and burning it in the combustion chamber, and then expelling it with great force out the exhaust system.
  due to the table's spinning. As they leave the table, the droplets' temperature suddenly plummets (by roughly 2,120 degrees Fahrenheit—1,000 degrees Celsius—in half a second), causing them to solidify and form a fine-grained metal powder. The resulting powder is very pure because it solidifies too quickly to pick up contaminants.
• 3 In the next step, the powder is packed into a forming case and put into a vacuum. Vibrated, the powder sifts down until it is tightly packed at the bottom of the case; the vacuum guarantees that no air pockets develop. The case is then sealed and heated under high pressure (about 25,000 pounds per square inch). This combination of heat and pressure fuses the metal particles into a disc. The disc is then shaped on a large cutting machine and bolted to the fan blades.

Compressor blades

• 4 Casting, an extremely old method, is still used to form the compressor blades. In this process, the alloy from which the blades will be formed is poured into a ceramic mold, heated in a furnace, and cooled. When the mold is broken off, the blades are machined to their final shape.

Combustion chamber

• 5 Combustion chambers must blend air and fuel in a small space and work for prolonged periods in extreme heat. To accomplish this, titanium is alloyed to increase its ductility—its ability to formed into shapes. It is then heated before being poured into several discrete, and very complex, segment molds. The sections are removed from their
  
  
  
  A jet engine is mounted to the airplane wing with a pylon. The pylon (and the wing) must be very strong, since an engine can weigh up to 10,000 pounds.
  molds, allowed to cool, and welded together before being mounted on the engine.

Turbine disc and blades

• 6 The turbine disc is formed by the same powder metallurgy process used to create the compressor disc. Turbine blades, however, are made by a somewhat different method than that used to form compressor blades, because they are subjected to even greater stress due to the intense heat of the combustor that lies just in front of them. First, copies of the blades are formed by pouring wax into metal molds. Once each wax shape has set, it is removed from the mold and immersed in a ceramic slurry bath, forming a ceramic coating about .25-inch (.63-centimeter) thick. Each cluster is then heated to harden the ceramic and melt the wax. Molten metal is now poured into the hollow left by the melted wax. The internal air cooling passages within each blade are also formed during this stage of production.
• 7 The metal grains in the blade are now aligned parallel to the blade by a process called directional solidifying. The grain direction is important because the turbine blades are subjected to so much stress; if the grains are aligned correctly, the blade is much less likely to fracture. The solidifying process takes place in computer-controlled ovens in which the blades are carefully heated according to precise specifications. The metal grains assume the correct configuration as they cool following their removal from the ovens.
• 8 The next and final stages in preparing turbine blades are machine-shaping and either laser drilling or spark erosion. First, the blade is honed to the final, desired shape through a machining process. Next, parallel lines of tiny holes are formed in each blade as a supplement to the interior cooling passageways. The holes are formed by either a small laser beam or by spark erosion, in which carefully controlled sparks are permitted to eat holes in the blade.

Exhaust system

• 9 The inner duct and the afterburners of the exhaust system are molded from titanium, while the outer duct and the nacelle (the engine casing) are formed from Kevlar. After these three components have been welded into a subassembly, the entire engine is ready to be put together.

Final assembly

• 10 Engines are constructed by manually combining the various subassemblies and accessories. An engine is typically built in a vertical position from the aft end forward, on a fixture that will allow the operator to manipulate the engine easily during build up. Assembly begins with bolting the high pressure turbine (that closest to the combustor) to the low-pressure turbine (that furthest from the cumbustor). Next, the combustion chamber is fastened to the turbines. One process that is used to build a balanced turbine assembly utilizes a CNC (Computer Numerically Controlled) robot capable of selecting, analyzing, and joining a turbine blade to its hub. This robot can determine the weight of a blade and place it appropriately for a balanced assembly.
• 11 Once the turbines and combustion chamber have been assembled, the high and low pressure compressors are attached. The fan and its frame comprise the forward most subassembly, and they are connected next. The main drive shaft connecting the low pressure turbine to the low pressure compressor and fan is then installed, thus completing the engine core.
• 12 After the final subassembly, the exhaust system, has been attached, the engine is ready to be shipped to the aircraft manufacturer, where the plumbing, wiring, accessories, and aerodynamic shell of the plane will be integrated.

I focused on only production process, about metallurgy etc... you can read more at How jet engine is made - material, manufacture, history, used, parts, components, dimensions, product, industry, machine, Design, Raw Materials, The Manufacturing Process of jet engine


We have 3 major companies regarding Turbine engines: Alp Aviation, KaleAero, TEI

Lets look at their production capabilities.;

Alp Aviation

Machining Envelopes are as follows (Inches):

• 5 Axis Machining Centers

• 5 Axis Large Size Machining Centers

• 4 Axis Horizontal Machining Centers

• 3 Axis Machining Centers

• 5 Axis Horizontal Turning / Milling Centers

• 5 Axis Vertical Turning / Milling Centers

• Vertical Turning Centers

• Centerless Grinding

• OD/ID Grinding

• CNC Ext/Int Spline Shaping

• Deep Hole Drilling

• 5 Axis Precision Jig Boring

• Jig Grinding- 5 Axes

• 3 Axis CNC EDM Machine

Fully Integrated Titanium Machining & Special Process House

Alp Aviation is a fully integrated titanium machining & special process house, with strong experience in machining & processing titanium wrought, forgings and castings.In order to provide finished titanium products and assemblies 4 & 5 axes precision machining equipment, in-house special processes and final acceptance tests are utilized.

·Cleaning
·Blue Etching
·Metal-Metal bonding
·Shot Peening
·Anodizing
·FPI (Fluorescent Penetrant Inspection)
·ECI (Eddy Current Inspection)

Special Process Capabilities

Heat Treat
Welding
Peening
Chemical Treatment
Topcoat
Bonding
Thermal Coating
EDM

Alp Aviation - Capabilities

KALE AERO

CNC operations (4&5 axes)
Special Processes , In-house coating, painting, heat treat, shot peen etc.

kaleaero.com

TEI

Machining

• CNC Turning
• CNC Milling
• CNC Grinding
• Jig Grinding
• Broaching
• Gear Shaping
• Automated Edgebreaking
• Abrasive Flow
• Vibrotary Machining

Fabrication

• 6 axis automatic and manual TIG welding
• Spot resistance welding
• Seam resistance welding
• Cold Forming and cutting
• Rivet joining
• Punch Press
• Air flow tests

Special Processes

• Thermal Spray Coatings
• Shotpeening
• Simutaneous Shotpeening
• Inertia Weld
• Elektrochemical Machining
• Dry Film Lubricant & Sermetel Coating
• Nickel & Crome Plating
• Rubber Seal Coating
• Macroetch, Blue Etch , Black Oxide
• Alkaline Cleaning & Titanium Cleaning
• EDM & Wire EDM & Stem Drill
• Chemical Milling
• Laser Cutting & Drilling
• Heat Treatment
• Brazing

TEI > Products & Services > Part and Module Manufacturing > Manufacturing Capabilities Machining

We are just doing the finishing job. Anyone who can buy the CNC machinery can do this. What should we focus is molding, founding, metallurgy, powder metallurgy etc... capabilities, meaning the critical capabilities.

Now, guys don't misunderstand me. I'm not saying we shouldn't go for turbine engines. We should go for them but understand that you are not making "kaşarlı tost". This is serious business which needs serious time, experience, qualified manpower and money.

 

[xxxKULxxx]

Now, guys don't misunderstand me. I'm not saying we shouldn't go for turbine engines. We should go for them but understand that you are not making "kaşarlı tost". This is serious business which needs serious time, experience, qualified manpower and money.

Yes, sure... And i agree with these things you say 100%...

 

[Hakan]

Even china couldn't build their own engine for their new 5th gen fighter.

Russia to supply engine for China's J-31 Jet

 

[rmi5]

@Sinan If you remember, there was a photo about timeline of turkish engine projects. I could not find it. Can you post it here?
Thanks

 

[-SINAN-]

@Sinan If you remember, there was a photo about timeline of turkish engine projects. I could not find it. Can you post it here?
Thanks

I was looking for it yesterday too but with no luck... Because of the new system, all old photos gone bad...

@cabatli_53 do you have that "Turbine engine road map" image ?

 

[cabatli_53]

 

[-SINAN-]

View attachment 150742

I wonder what happened to 3.1 kn Turbofan project.....?

@xxxKULxxx you got any news about that project ?