RuAviation

Developing an aero engine is a complex and lengthy process, typically taking around ten years. For instance, the PD-14 engine for the MC-21-310 aircraft took just that long. However, engineers at ODK-Klimov managed to create the new VK-650V turboshaft engine (TSE) for light helicopters in just five years.

Work on the preliminary design of the VK-650V began in Q3 2019. A demonstrator engine was built just six months later. This was made possible by using modern technologies, digital twins and additive manufacturing, as well as a high degree of co-operation between leading enterprises in the sector: ODK-Klimov, Salyut, ODK-UMPO, MMP named after V.V. Chernyshev, TsIAM and VIAM.

The main task set for the ODK-Klimov engineers was to create a TSE with a simple and reliable design, and with minimal lifecycle cost. At the same time, the development timeframe was extremely tight. Just four years were allocated for research, development and experimental design work (R&D). In order to meet these deadlines, it was necessary to forego potentially risky technical solutions that might have improved engine performance, but would have required additional research and testing time.

For example, fuel consumption could have been improved by increasing the gas temperature ahead of the turbine or increasing the compression ratio, but this would have affected engine life. There simply wasn’t time for such experiments, and the decision was made to focus on proven technologies.

In January 2021, testing of the demonstrator engine began on a purpose-built test stand in St. Petersburg. Klimov specialists installed a power frame, hydraulic dynamometer, fuel and oil system, and a modern control console. The engine was started by an electric starter-generator. During testing, the operating parameters of the units, assemblies and gas generator were continuously recorded, and the condition of the engine was visually assessed. The results were successful: ignition of the fuel-air mixture in the combustion chamber occurred first time, without prior independent testing and debugging of the ignition system.

To reduce electromagnetic field levels, radio-absorbing materials were used in the engine’s automatic control system. This increases the system’s resistance to electromagnetic interference and makes the engine safer. At the MAKS air show in July 2021, representatives from ODK-Klimov announced that the second phase of demonstrator testing was underway. Following this, three prototypes were planned for manufacture and engineering tests would commence.

In 2022, two VK-650V prototype engines were manufactured at Klimov. By May of the following year, their engineering tests had been completed. Independent tests of the compressor and combustion chamber were conducted jointly with TsIAM. This allowed the project to move to the next phase – certification testing, which took place in 2024.

In the summer of 2024, an Ansat helicopter with VK-650V engines installed was demonstrated at the Army forum. At the same time, its preparation for flight tests was reported. Moreover, in the autumn of last year, at the Mil and Kamov National Helicopter Centre near Tomilino, outside Moscow, the first hovering flights of another light helicopter fitted with the VK-650V engine – the Mi-34M1 – were carried out.

In December 2024, Rosaviatsia issued a type certificate for the VK-650V engine, which was handed over to ODK-Klimov in February 2025. This is official confirmation that the engine meets all requirements and is ready for series production.

According to data sheet FATA-01065E, the VK-650V is certified in a variant with a power output of 545 hp in take-off mode. In maximum continuous mode, the power output is 460 hp, and in cruise mode, 400 hp. In contingency mode, with one engine inoperative, the VK-650V develops 630 hp for 2 minutes 30 seconds, and in continuous power mode, 590 hp. At this stage, the VK-650V is certified with a time between overhauls (TBO) interval and an initial free turbine shaft life of 74 hours 36 minutes. The initial life of the remaining major components is set at 100 cycles.

It is anticipated that, following further certification testing, major change approvals will be sought, aimed at increasing the life of hot section components to 4,500 hours, cold section components to 9,000 hours, and increasing power to the design values – 650 hp in take-off mode and 750 hp in 2.5-minute contingency mode.

According to the head of the Ministry of Industry and Trade of the Russian Federation, Anton Alikhanov, certification flights of Ansat helicopters with VK-650V engines will begin shortly, and are expected as early as April. Completion of the certification process is scheduled for the end of 2025. However, in an interview with the Rossiya 24 television channel on 27 February, the minister suggested that this could happen slightly earlier – by October. The comprehensive aviation industry development programme forecasts the manufacture of the first eight series-production VK-650V engines this year. Subsequently, from 2029, the production volume will be increased to 70 units per year.

The creation of the VK-650V engine in five years was the result of the well-coordinated work of the ODK-Klimov team, related enterprises, and research institutions. Engineers and scientists were able not only to meet tight deadlines, but also to create a product that will be able to replace imported power plants on light Russian helicopters. The aero engine industry, which fell into complete disrepair in the 1990s, the consequences of which we are still feeling, is being reborn. Proof of this is the PD-8 and PD-14 turbofan engines, the TV7-117ST-01 turboprop, and the VK-650V turboshaft engine.