As part of the project to localize the MS5002E gas turbine unit, the import substitution stage of metallurgical workpieces for high-pressure turbine (HPT) and low-pressure turbine (LPT) disks in accordance with the requirements of original foreign standards has been completed. Workpieces of the required chemical composition, weight and size characteristics according to the standards of foreign manufacturers were produced in Russia for the first time.

"The project to produce the first domestic workpieces required special competencies and experience of a large number of specialists - both employees of “REP Holding” and other specialized Russian factories and institutes, who showed a high level of professionalism at the stage of mastering materials, selecting and evaluating technological solutions during the project implementation," said Alexey Gorin, Director of production development at “REP Holding” JSC, “The production of the first samples required immersion in basic science and a systematic approach with intermediate control of each stage of development. All stages were controlled by engineers of the design and technical department of the “REP Holding” and, to a large extent, thanks to the vast experience of the metallurgists of the Nevsky plant, suitable workpieces were obtained during the experimental work."
Production of HPT discs of Inconel 718 nickel alloy obtained by triple remelting (VIM, ESR, VAR) has been mastered. The workpieces have been obtained by hot working, using a hot-forging press with an effort of 12000TF. Verification of the properties and quality of the blanks was performed in cooperation with the All-Russian Institute of Aviation Materials (FGUP "VIAM") and Central Institute of Aviation Engine Building (FGUP “CIAM"). The cooperation of specialists of the REP Holding engineering department, Stupin Metallurgical Company, researchers of VIAM and CIAM has made it possible to successfully cope with the task.

The low-pressure turbine disc workpieces are also fully manufactured from martensitic stainless steel according to ASTM standards. The smelting of this alloy was actually carried out by the selection of the chemical composition of the material by specialists of the Chelyabinsk enterprise BVK LLC. Forging, heat treatment, analysis and adjustments of processes were carried out under the control of engineers of "REP Holding".

At this stage, discs, shaft ends, LPT shaft, internal rings and LPT casings have been mastered. Based on the results of the scientific and technical council conclusion, the use of low-alloy steel equivalents has been approved, with the requirements of the licensor’s technical documentation strictly complied with. Specialists of the Nevskiy Plant laboratory have verified the obtained mechanical properties and workmanship of die forgings for all stages of the GTU-32 axial compressor blades.

Stampings and forged workpieces are made of dispersion-hardening stainless steel, which has no analogues in the Russian classifier. Specialists of the Nevsky plant together with metallurgists of the enterprises of "Kaluga engine" PJSC, "ARTOM" LLC and "Ruspolimet" PJSC performed adaptation and full import substitution of these workpieces. All operations were performed in accordance with ASTM and SAE Int. standards, which is the first experience of Russian metallurgists for these brands of materials.

Import substitution for metallurgical workpieces in shaped casting within the framework of the localization program for MS5002E turbine rated at 32 MW which is part of the gas-pumping unit "Ladoga" has been completed in full.

"In the second half of 2020, the possibility of serial production of the compressor casing castings will be confirmed, which is the final step for full localization of shaped casting for the MS5002E turbine casing parts. In addition, in the fourth quarter, shroud blanks of Hastelloy X material will be delivered, which will be also the final stage of import substitution for metallurgical semi-finished products used in the manufacture of the gas turbine engine," said Aleksey Kiselyov, metallurgical workpieces localization program manager, “REP Holding” JSC Advanced Projects Department.