Committed to the mission Military engine programs Leading engine manufacturer MTU Aero Engines is Germany’s leading engine Strong and capable manufacturer and a key player in the industry both in Germany and on an international level. partner The company designs, develops, manufactures, markets and supports commercial and military Innovative, capable and reliable—with its first- propulsion systems and industrial gas turbines, class technologies, products and services, MTU and offers full system capability in engine con- ensures that military customers can count on struction. In close cooperation with the world’s the full availability of their fleets at all times. It is leading engine manufacturers as well as part- the leading industrial company for practically all ners from industry and research, MTU is devel- engines operated by the German Armed Forces oping the innovative propulsion systems of the and plays a key role in major European military future. It participates in advanced technology engine programs. Mutual trust, proximity to the programs, providing valuable impetus with its customer, reliability and expertise: these are the developments. MTU’s low-pressure turbines, foundations for a successful engine partnership low-pressure compressors, high-pressure com- in the military arena. Together with its customers, pressors and control systems are some of the MTU works to develop and implement tailored best in the world. Its manufacturing processes, service support concepts to meet individual re- repair techniques and comprehensive service quirements quickly and reliably. MTU’s compre- offerings are some of the best the global market hensive support services throughout an engine’s has to offer. MTU’s expertise has a long history, lifecycle—from development and manufacture, the company’s roots date back to the early days customized maintenance, facility and training of powered aviation. For more than 80 years concepts, right up to the provision of technical now, the military business has formed the basis documentation and on-site support—enable part- of the company’s system capabilities. Over the ners such as the German Armed Forces to secure decades, MTU has repeatedly set technological valuable know-how in their own ranks. This ap- benchmarks to drive forward the development proach has proven highly successful worldwide. of aviation, initially for military aircraft and later for the commercial sector too. Thanks to its experience, expertise and innovative strength, Full system competence the company has carved out a position for itself as a technology leader in key areas and has Alongside the development and manufacture established itself as a must-have partner. of innovative engine modules and components, MTU offers the best in maintenance, repair and overhaul solutions, smart repairs and support with a comprehensive range of additional engine services. With such an extensive portfolio, MTU is well prepared to support the entire lifecycle of an engine. Full system competence from a single source guarantees a high degree of flexi- bility, quick response times and in-depth dialog between individual areas. A tried-and-true basis for ensuring mission success. High-tech manufacturing: A blisk for the intermediate- pressure compressor of the TP400-D6 is machined on a 5-axis milling system. 2 3 World-class technology MTU Aero Engines is one of the world’s leading requirements and strategic considerations. development partners and contributes its exper- Thanks to its extensive technology portfolio, tise to newly developed propulsion systems, MTU can also supply components across all such as the T408 powering the CH-53K heavy- phases of the engine life cycle. lift helicopter and the TP400-D6 for the A400M military transport aircraft, while also specializing in models that have been in service for many Technologies for the years, such as the RB199 engine for the Tornado, the EJ200 engine for the Eurofighter Typhoon engines of tomorrow and the MTR390 engine for the Tiger. MTU’s broad experience forms a solid basis of unique MTU has identified various future technologies expertise for the new and further development for the next generation of engines and will con- of advanced engine components and the asso- tinue to develop them. These include multidis- ciated control systems. ciplinary processes and simulations used for the design of the engine concept and with com- ponents, for example the digital twin. New pro- Strong in technology duction processes such as additive manufactur- ing and the incorporation of bionic design enable development new designs and structures. Enhanced engine sensor technology together with data evaluation MTU files more than 400 patent applications and methods improves analysis and forecasting in makes 200 invention disclosure reports every ongoing operations. New designs and innovative year—a testament to the company’s innovative materials such as fiber-reinforced ceramics capabilities, which are also the result of a com- reduce the weight and also allow for higher prehensive technological process that the com- engine temperatures. In the field of mainte- pany uses to implement commercial and military nance, augmented reality methods significantly innovations on time and within budget. This pro- enhance process validation and also help reduce cess systematically focuses on future product costs. Innovative support: The use of augmented reality (AR) technology in the future will accelerate maintenance and repair processes. 4 Specialist for the most important components MTU Aero Engines has established itself as a world leader in key engine technologies: its com- pressors, turbines and control systems are among the finest to be found in the global marketplace. Efficient compressors High-pressure compressors are the centerpiece of an engine. For more than 30 years, the compa- ny has been developing, manufacturing, repairing, and overhauling this engine module. Today’s com- pressors are built on the blisk principle, where the disk and blades are manufactured as a single part. Flagship MTU products are the military com- pressors for the EJ200 engine that powers the Assembly of a low-pressure Eurofighter Typhoon and for the TP400-D6 engine calls for new materials, which undergo extensive compressor for the EJ200: MTU developed the low-pressure and that powers the A400M military transporter. testing in a technology demonstrator. The basis high-pressure compressors as well for this engine demonstrator is an MTR390. as the electronic control unit, and Award-winning turbines manufactures these components MTU has carved out a world-class technological Advanced control systems for all Eurofighter Typhoon engines. position for itself in the commercial sector in the When it comes to control systems, MTU can draw field of low-pressure turbines. An excellent exam- on valuable experience gained from the EJ200 ple of this is its high-speed low-pressure turbine engine as well as know-how from other military that operates at maximum efficiency. This exper- programs and the commercial sector. The real- tise can also be extended to the military sector. time monitoring systems we use in this sector For engines to operate even more efficiently, with their analysis and forecast capacities allow temperatures must be increased. This in turn us to detect damage early on and to prevent it. The company’s broad experience and exclusive know-how form a solid basis for the development and refinement of advanced control systems. 5 MTU developed not only the PECM process for the manufacture of nickel blisks, but the machines as well—currently in operation in Munich. One of these is selective laser melting, which State-of-the-art helps produce complex components almost with- production out the need for conventional tooling. Further advantages afforded by additive processes are Engines used in military operations are subjected markedly greater freedom of design, shorter pro- to extremely high stresses that vary greatly with duction times, faster innovation cycles, lighter the respective missions and operating environ- components with added functionality and lower ments. For this reason, MTU develops special development costs. MTU has achieved a break- production processes for such highly stressed through in engine production: having introduced components, which it optimizes continuously. additive processes to its operations in 2013, it is one of the first companies to manufacture Blisk technology components using such methods on an indus- Rotors featuring a blisk (blade integrated disk) trial scale. design, originally developed for the EJ200, are now used in compressors for commercial engines too. MTU has established itself as one of the world’s leading blisk manufacturers. At its site in Munich, Germany, the company operates one of the most advanced compressor blisk production systems of its kind. High-tech processes Among the most important high-tech processes are laser caving to produce cooling air holes in high-pressure turbine airfoils, as well as adaptive milling, broaching, friction welding and precise electrochemical machining (PECM). Additive man- ufacturing processes are gaining in importance. A prime example of MTU’s manufacturing expertise are its compressors in blisk design for the EJ200 engine that powers the Eurofighter Typhoon. 6 7 Intelligent maintenance solutions MTU Aero Engines offers its military customers Smart maintenance comprehensive support. In addition to conven- tional engine maintenance and smart repairs,