The “single crystal fin casting” studies, which are considered as a critical technology stage in turbine engines, were initiated in 2016 with the KRİSTAL Project, supported by the Defense Industry Presidency R&D and Technology Management Department, in cooperation with TEI and TÜBİTAK MAM. In light of the scope of this project, acquired knowledge and experience, Turkey's first national TEI-ts1400-cooled engine helicopters to be used in high-pressure turbine and completed the production of uncooled turbine blades TEI was delivered. Turbine blades for the first time, Turkey's leading company in the aerospace engines TEA - TAI Engine Industries Inc. designed, developed, produced and operated by; Turkey's first national helicopter engine TEI-ts1400 number of engines to be used in TS5.
Turbine blades, one of the most critical parts of aviation engines, are exposed to high temperatures under operating conditions, versatile forces and requirements to protect the integrity of parts and engines under challenging environmental conditions; It is produced from nickel-based super alloy, single crystal structure, by precision casting method. These parts are suitable for working at temperatures up to 1400 ° C with their extremely sensitive cooling channel designs, and an important step was taken thanks to the simultaneous development of single crystal castings, subsequent heat treatment and non-destructive control methods.
Single crystal cast fins produced by TÜBİTAK MAM with high quality standards will be used first in the ground tests of the TEI-TS1400 engine, and in the later stages of the project, in the certification processes that are very critical for aviation and then in the final engine.
TÜBİTAK President Prof. Dr. Hasan Mandal, TEI General Manager and Chairman of the Board Prof. Dr. Mahmut F. Aksit, President of TÜBİTAK MAM Dr. Osman Okur, Material Institute Director Prof. Dr. Metin Usta, Chief Expert Engineer Assoc. Dr. In addition to Havva Kazdal Zeytin, managers and employees of TEI and TÜBİTAK MAM project teams attended.
Prof. Dr. In his speech at the ceremony, Mandal said that as a result of the cooperation of TÜBİTAK MAM and TEI, the single crystal turbine blades, which are among the most critical technologies of aviation engines, have been successfully produced.
Emphasizing that both the refrigerated system and the non-refrigerated system cover a learning process from design to production, Mandal said, "I think that besides the production in question, the competence and talent and material technologies we have gained here are also important for the development and sustainability of our country, especially in the defense industry." said.
Mandal stated that they developed turbine blades working under difficult conditions and sometimes impossible to import with TEI and delivered the first set.
“This is really an important achievement for our country. The following was always said about local and national production; "Yes, you have a helicopter, but is it a local engine?" Yes, TEI can produce it locally. Yes, there is an engine, but can the components inside the engine be produced locally and nationally? Yes, we are now able to manufacture the turbine blades, the most difficult component of our country's first domestic and national turboshaft engine, as TÜBİTAK MAM. This technology is very critical and a very limited number of countries in the world have this technology. It is a very complex and difficult design, it is not easy to do them. We made it happen. Of course, this is not a finished process. There is surely a continuation. With the Aviation Engine Materials Development - Ore Project signed yesterday, TÜBİTAK Materials Institute and TEI will now be able to produce nickel-based superalloys for these and similar applications starting from raw materials.
TEI Chairman of the Board and General Manager Prof. Dr. Mahmut F. Aksit shared that he was also a Member of the Board of EÜAŞ when he was a faculty member at Sabancı University, and explained that they made similar initiatives for the blades needed by industrial gas turbines at that time and that they brought the infrastructure in question to TÜBİTAK MAM.
Akşit pointed out that even if they sell the turbine blade, which is one of the most important parts of aviation engines, they do not share the technology, how it is produced and such things, and stated that they decided to develop the wing technology here because they knew the infrastructure of TÜBİTAK MAM.
Emphasizing that although the fins used in aircraft engines are smaller, it is a higher technology and a more difficult process, Akşit said, "Thank God our friends at the TÜBİTAK MAM Materials Institute have achieved this with their foreheads and brought us the wing technology we needed." said.
Akşit stated that the blades received were not the first turbine blades produced by TÜBİTAK, these blades were used in the TEI-TS1400 engine, which they previously delivered to TAI, but they could not hold a ceremony at that time.
Stating that they bought the previous turbine blades gradually as they completed it, Akşit said: “What you see here is a complete engine set. Both the first stage single crystal, internally cooled blades, which is much more difficult, and the second stage is also a single crystal but without internal cooling blades. We aim to use this in our TS5 number engine. These wings were also used in the engines we previously supplied to TAI. This is the full set of our TS5 engine. It was the first time to see them together as a full set. "
Stating that they produced the engine numbered TS4 and that their tests are continuing, Akşit said, “We delivered our first national helicopter engine TEI-TS5 on December 1400. These blades will be mounted on our TEI-TS5 engine numbered TS1400, I hope. I hope they will work on the Gökbey helicopter. " he spoke.
Pointing out that when the most critical parts in an engine are listed, first-stage blades come first, Akşit said, “Then maybe the combustion chamber may come, then second-level blades come in terms of temperature and technology difficulty. The compressor side is also very difficult, but the most difficult is the first stage single crystal wings. The most critical parts. If you cannot do this, I will not say that you cannot start the engine, but you cannot generate power. You cannot go to high temperature. " used the expressions.
Akşit said the following regarding the function of single crystal turbine blades in engines:
“All jet engines, like other fossil fuel engines, work with the expansion of the warming air. How do we heat the air? We put the fuel in it and strike the match so that the air warms up and expands. In order to do this, we have to compress the air from the compressor. If we do not compress the air, the combustion event will be very slow and we get much lower power from the same engine. The power we obtain per unit time decreases. That's why we deliver it to high pressure. In order to burn more efficiently, get more output from the engine per unit time. As such, instead of using the gas ejected from the back in direct impulse, we convert some of the energy there into rotational motion by hitting these hot fins, which supports the squeezing of the air in the compressor. Without these blades, the engine would not work. In other words, these blades operate the compressor by consuming considerable power. "
Following the delivery made after the speeches, the event ended after the guests visited the High Temperature Materials Research, Development and Repair Center of Excellence.