RuAviation

The Rybinsk-based enterprise UEC-Saturn has introduced friction welding (FRW) for the serial production of gas turbine engine components. This marks the first facility within United Engine Corporation (UEC) to adopt this technology for mass production, according to the UEC press service.

Friction welding enables the joining of dissimilar materials, including those unsuitable for conventional fusion welding. The process relies on localized heating at the contact interface, where one component rotates at high angular velocity while the other remains stationary. The temperature in the thin surface layer rises sufficiently to allow plastic deformation and the formation of a robust joint, without melting the base material.

Previously, UEC-Saturn utilized electron beam welding for manufacturing SaM146 engine rotors. The new method, now applied to PD-8 engine production, ensures 100% weld integrity and reduces operation time by a factor of ten. In 2024, the facility installed a domestically produced PST-100C machine, streamlining production and enhancing part quality.

Friction welding significantly reduces defects associated with thermal stresses and microcracking, which are common in electron beam welding. It also expands the possibilities for joining advanced alloys used in aerospace engines, noted a UEC representative.

The substantial reduction in welding time directly accelerates the overall production cycle. Increased throughput is critical to meeting the target of at least 54 PD-8 engines annually by 2028, as outlined in Russia’s Comprehensive Aviation Industry Development Program. Furthermore, 100% weld integrity eliminates scrap, reduces quality control costs, and minimizes rework. Collectively, these factors ensure schedule stability, minimize downtime, and ultimately determine project profitability.

For the PD-8, as a new generation of Russian aircraft engines, the adoption of advanced welding methods supports the achievement of required operational characteristics—service life, reliability, and maintainability. The flexibility of these technologies also enables rapid design modifications to meet customer requirements, optimizing processes without compromising quality.

Friction welding is a well-established global standard, widely used for manufacturing rotors and shafts in gas turbine engines. Its implementation at UEC-Saturn establishes a reliable technological foundation for stable serial production of the PD-8.