Specialists from the United Engine Corporation (UEC) explained how aircraft engines undergo the most stringent multi-level checks before release: even a deviation of 10 micrometers - only one-tenth the thickness of a human hair - is considered critical. Such minimal errors can reduce engine efficiency by 1-2% and cause dangerous vibrations, so each unit undergoes detailed diagnostics at all stages of production.
The verification process is divided into three key stages.
1. Micron-level geometry control
Before assembly, each part undergoes a visual inspection for scratches, traces of corrosion, and the condition of the joints. Then, laser scanners and coordinate measuring machines are used to record deviations in geometry with an accuracy of up to a micron. Without confirmation of compliance with these parameters, the engine is not allowed for further testing.
2. Non-destructive testing: "X-ray for metal"
To identify internal defects, methods unavailable to the naked eye are used:
- eddy current testing - for analyzing the surface of the blades;
- radiography - for detecting voids or foreign inclusions inside parts;
- ultrasonic and magnetic particle flaw detection - for finding hidden cracks.
3. Bench tests: a full cycle of flight simulation.
On the test bench, the engine undergoes comprehensive testing:
- warm-up and adjustment of all systems;
- start-up and operation in the entire range of modes - from idling to take-off thrust;
- modeling take-off, climb, and cruise flight;
- long-term operation in various modes to confirm the declared service life and power;
- monitoring vibrations, temperature fields, pressure in nodes, fuel consumption and parameters;
- analysis of oil for the presence of metal shavings as a sign of internal wear.
UEC noted that there are no secondary parts in engine construction - each element undergoes the most stringent control, since flight safety depends on accuracy measured in microns.