Committed to the Mission Military Engine Programs Leading Engine Manufacturer

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 flexibility, 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 components, for example the digital twin. New pro- Strong in technology duction processes such as additive manufacturing 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 compressors, 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 company has been developing, manufacturing, repairing, and overhauling this engine module. Today’s compressors are built on the blisk principle, where the disk and blades are manufactured as a single part. Flagship MTU products are the military compressors 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 manufacturing 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 conventional engine maintenance and smart repairs, concepts customers benefit from a wide range of services that are tailored to satisfy its military partners’ Using engine health monitoring, extensive moni- specific needs. toring of various engine parameters, and analyz- ing the condition of the engine based on this data, MTU experts can detect unusual operating Innovative repairs conditions and identify countermeasures before the problem even occurs. As the next logical increase availability step, MTU plans to develop smarter analysis models based on a higher sensor density, which Innovative repair techniques optimize engine will perfect the process. This will enable opera- availability and reduce costs. Based on many tors to schedule maintenance before an incident years of experience and a fully integrated devel- results in unplanned downtime, thus increasing opment process, MTU is continuously building availability of their weapon system. In addition, on its high-tech repairs so that lifecycle costs the use of augmented reality (AR) technology continue to decrease. Examples of its compre- in the future will accelerate maintenance and hensive repair expertise include adaptive milling repair processes. to restore damaged compressor blade tips and innovative coating methods for protecting compressor airfoils from erosion.

EJ200 teamwork: Specialists from the German Air Force work shoulder to shoulder with MTU experts as part of their collaboration.

8 An RB199 on the test stand: MTU now focuses on spare parts production, repair and service offerings for the engine that powers the Tornado.

Comprehensive service Going by the motto “Committed to the mission”, MTU Aero Engines aims to satisfy all of its military customers’ operational requirements. Its comprehensive services range from technical customer support and spare parts support when needed all the way to smooth fleet management and the comprehensive compilation and maintenance of documents and tailored training oppor- tunities. The service support concepts are flexi- ble and tailored to the respective lifecycle of the engine and the customer’s specific setup and Another example of MTU’s comprehensive repair requirements, and thus provide the all-round expertise is adaptive milling to restore damaged support they need to ensure smooth operations. compressor blade tips.

Two strong partners the military propulsion systems. The combi MTU’s collaboration with the German Armed nation of MTU’s technical expertise and the Forces is a prime example of its ability to devel- military’s operational experience ensures highly op and implement service concepts tailored to industrialized and cost-effective maintenance customers’ specific needs. MTU supports a large operations. Involving military personnel in the share of Germany’s propulsion systems and in maintenance and repair work, in quality assur- 2002 it was the first company to successfully ance management, logistics and in service sup- establish a cooperation of this kind with the port in this way secures the assessment skills German Armed Forces. Since 2014, work on the and technical abilities of the German Air Force EJ200, RB199 and MTR390 programs has been and Army long term. The cooperation will be performed under the same roof in Erding, Bavaria. further expanded, the ultimate goal being to MTU experts and specialists from the German ensure full availability of the engines operated Air Force work shoulder to shoulder to maintain by the German Armed Forces at all times.

9 Power for the military

MTU delivers excellent performance, now and in the future.

MTU Aero Engines is one of the world’s leading high payloads over long distances. Development industrial system partners for the military engines and production of military engines calls for the that power combat jets, helicopters and military combined expertise of several highly specialized transport aircraft. Propulsion technology for mili- companies, including MTU. Each bringing their tary aircraft is geared toward maximum availabil- specialist skills to the table, the participating part- ity and long on-wing times. Where helicopter ners join forces to ensure the overall success of engines are concerned, MTU applies its expertise the engine program. At a European level, MTU with advanced turboshaft engines and makes a cooperates with all of the leading players in the valuable contribution to U.S. programs with its industry and contributes its technological exper- development activities. The company moreover tise to provide first-class products and services, provides powerful propulsion solutions for mili- as can be seen from the following examples: tary transport aircraft that are required to carry

MTU Aero Engines’ component know-how

Low Inter High Combustion High Inter Low Thrust Casing Gearbox Engine Mainte pressure mediate pressure chamber pressure mediate pressure/ reverser control/ nance, compressor pressure compressor turbine pressure power monitoring repair and compressor turbine turbine overhaul

Fighter EJ200 Aircraft F110 F414 Larzac 04 RB199

Helicopters T408 MTR390 T64

Transport TP400-D6 Aircraft Tyne

MTU Aero Engines’ component know-how Maintenance, repair and overhaul under the cooperation with the German Armed Forces Maintenance, repair and overhaul at MTU Aero Engines

1 NAVAIR Public Release 2018-259. Distribution Statement A – “Approved for public release; distribution is unlimited”

10 EJ200 for the MTR390 for the Eurofighter Typhoon Tiger combat helicopter

A two-shaft turbofan engine with an afterburner, Developed in cooperation with Safran Helicopter the EJ200 is built by EUROJET Turbo GmbH, a Engines and Rolls-Royce, the MTR390 is a turbo consortium with MTU, Rolls-Royce, Avio Aero shaft engine featuring a free power turbine. It and ITP Aero as stakeholders. The engine pow- powers the Tiger support helicopter co-devel- ers the Eurofighter Typhoon. MTU developed the oped by France and Germany. MTU’s workshare low-pressure and high-pressure compressors as comprises the core engine—the combustor and well as the electronic control unit, and manufac- gas generator turbine—and some of the engine tures these components for all EJ200 engines. In accessories. In collaboration with ITP Aero, MTU addition, the company is responsible for assem- has developed an upgraded version of the engine bly, testing and repair of all engines operated (the MTR390-E) that delivers 14 percent more by the German Armed Forces and the Austrian power. All production engines are assembled at Armed Forces. MTU.

TP400-D6 for the A400M Partner of the military transport aircraft U.S. military The TP400-D6 for the A400M military airlifter is As a risk-and-revenue-sharing partner of GE the most powerful turboprop engine of the West- Aviation, MTU holds stakes in the F414, F110 ern world. It is developed and built jointly by MTU, and T408 programs. MTU’s workshare in the Safran Aircraft Engines, Rolls-Royce and ITP Aero. T408 for the CH-53K heavy-lift helicopter, the MTU is responsible for manufacturing and main- latest model in the CH-53 series produced by taining the TP400-D6’s intermediate-pressure Lockheed Martin/Sikorsky, marks another mile- compressor, turbine and shaft and has a stake in stone in its collaboration with its U.S. partner. several accessories. Furthermore, final assembly MTU develops and manufactures the power tur- of all TP400-D6 production engines and mainte- bine—the first time it has full responsibility for an nance work for the German Armed Forces takes entire module in a U.S. military engine program. place at MTU Aero Engines in Munich and accept- Compared to its predecessor, the T64, the T408 ance testing takes place on the test stand at MTU is 1.7 times more powerful and delivers an 18 Maintenance Berlin-Brandenburg. percent reduction in specific fuel consumption.

Full command of complex systems: Assembly work on MTU is responsible for the development and manufacture the TP400-D6 for the A400M military transport aircraft. of the power turbine and will obtain licenses for maintenance, final assembly and testing of the T408 models to power a future European heavy-lift helicopter.1

11 First-class quality for safe operations

The products and services that MTU Aero Engines Certifications deliver fulfil the highest standards of quality and • ISO 9001:2015 reliability to which certifications and approvals • ISO 14001:2004 from major worldwide airworthiness authorities • EN 9100:2018 testify. To ensure such high quality standards • BS OHSAS 18001:2007 are maintained, the company places particular • EMAS emphasis on continuous improvement in its engine development, production and maintenance Approvals activities. All products and processes are contin- • Certificate of approval as a Contractor for uously monitored and subjected to regular inter- German Armed Forces Aeronautical Equipment nal audits to identify and leverage all improve- as per A1-1525/0-8901 ment potential—a strength from which all those • Design organization approval as per involved benefit. The success of any company EASA Part 21J is contingent on the expertise and commitment • Production organization approval as per of its workforce. MTU’s employees are highly EASA Part 21G motivated and highly qualified specialists in their • Maintenance organization approval as per fields. Dedicated young professionals work along- EASA Part 145 side seasoned experts, all invaluable assets to • Maintenance organization approval as per the company. Training and development of its CFR 145 employees’ professional and personal skills are • Maintenance organization approval as per high on the agenda at MTU. In this way, MTU CAR 573 makes sure its workforce remains highly quali- • Maintenance organization approval as per fied and internalizes the exacting quality stand- CAR 145 ards stipulated by the company and its military • Maintenance organization approval as per partners—putting them into practice in day-to- CCAR 145 day operations and continually developing them. • Maintenance organization approval as per First-class quality management ensures consis DEMAR 145 tently high quality standards across all parts • Authorized Economic Operator (AEO) and modules. MTU holds the following approvals authorizing the company to develop, manufac- International specifications ture and repair airworthy engine components • Preparation of technical documentation and modules. as per ASD S1000D • Material management as per ASD S2000M

Highly qualified and motivated: MTU employees Under scrutiny: the human eye is and remains an No compromises: Delivering consistently high have internalized the high quality requirements. important instrument for quality assurance. quality has top priority at MTU.

12 Full power ahead

Three T408 engines deliver all the power the CH-53K transport helicopter needs.

With its broad portfolio of products and main tenance services for commercial and military engines, MTU Aero Engines is in an excellent posi- The requirements for a next-generation for the future. As a well-established player tion fighter aircraft have been clearly defined, among them increased sur- in the industry, the company has secured stakes vivability, maximum range and high in major next-generation engine programs—for mission flexibility. example in Pratt & Whitney’s GTF™ Engine Family of energy efficient GTF™ engines. MTU’s work- Working in partnership with Safran Aircraft share in these engines includes components for Engines, MTU will develop, manufacture and the high-pressure compressor and the high- support the engine to power Europe’s Next speed low-pressure turbine. Generation Fighter (NGF). This engine, known as the Next European Fighter Engine (NEFE), will shape Europe’s military engine business for Committed to mission decades to come. As part of this partnership, MTU will contribute its flagship high-pressure success and low-pressure compressors. It will also take responsibility for the low-pressure turbine and MTU is also well positioned for the future in its control systems and provide maintenance military business. The process to procure a new and support from development to operation. heavy lift helicopter for the German Armed Forces is underway. Lockheed Martin subsidiary Sikorsky Thanks to its many years of experience in the Aircraft has entered a bid for the contract with its military business, its technological expertise and CH-53K King Stallion powered by GE Aviation’s its know-how in supporting engines across their T408 engine. The team of German industry part- entire lifecycle, MTU is well positioned to find and ners also includes MTU, which supplies the power implement the best solution for its military cus- turbine and repair work in Germany for this tomers. MTU continues to prove itself as a relia- powerful engine. ble partner to the military—now and in the future.

13 www.mtu.de [email protected] Fax +49891489-5500 Phone +49891489-0 80995 Munich •Germany Dachauer Straße665 MTU Aero EnginesAG

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