1. Mr. V V Kiryukhin, Chief Designer, Lyulka SATURN, Moscow. 13,Kasatkin Street, Moscow- 129301 Fax: 007-495-6867566.
2. Mr. Igor Chechikov, JSC OBORONPROM, MOSCOW, 29/141, Vereiskaya Street p/o: #26, , 121357 Moscow, Russia Fax: 007-495-2236414, 7975548.
3. Mr. A N Permyakov Director License Programme UMPO, UFA 2 Ferina Street, 45003 Russia Telex: 162340RICA RU Fax: 007-3472-383655. 4. Rpt: RM, Moscow
Sub: Improvements in Bearing Design to preclude recurrent failures of AL31FP engines.
Operational confidence level of the Indian Air Force has significantly reduced due to recurrent premature failures of AL-31FP Engines and increasing trend of single engine emergency landings. Details of 41 cases of single engine emergency landings were discussed in various forums such as IRSA and Tripartite Meeting at Air HQ with OEM representatives. Of the total 41 cases, 11 cases were due to Bearing failures (Inter Rotor and Inter Shaft Bearing). Failure of both these Bearings could be the manifestations of various serious Design deficiencies in the present Design for AL-31FP engines which are to be identified explicitly on the highest priority, and the Design modifications are to be incorporated in a time bound manner in order to boost the diminishing confidence level of the Indian Air Force.
Contd 2
--2-- As a way forward Russian side has proposed 20 recommendations (11 for Manufacturing and 9 for Exploitation) after Joint Investigation was carried out along with Indian side. Recommendation is given for modification of Inter Rotor bearing (Part No: 5-272822P2Y) with improved cooling of the Bearing by introduction of additional Lubrication oil supply holes. Indian side is of the opinion that this recommendation is a short term solution to the Bearing failure problem. Other critical design aspects such as Material characteristics of the Bearing races and Rollers, Micro-structural changes leading to plastic deformation during operation, Material erosion and Load characteristics need to be introspected and validated. Preliminary findings/Analysis of the Cat-A Bearings vis a vis failed Engine Bearing reveal the following: 1. Inter-shaft bearing (55-2672919P5): a. Abrasive wear and moisture corrosion observed on raceway with discoloration of outer ring. b. Plastic deformation of inner ring with discoloration and abrasive and adhesive wear on raceway. c. Crack initiation on almost all cage pockets. d. Spalling observed in cage pockets at roller contact. e. High ovality noticed on inner and outer rings. f. Signs of overheating seen with micro-structural changes leading to deformation. g. Hardness profiles of outer ring showed low hardness values from raceway to core rather than from outer diameter to core which confirms heat generation is high on raceway compared to outer diameter. 2. Inter-rotor bearing (5-272822P2Y): a. Outer ring and inner ring raceways shows false brinelling marks, spalling and plastic deformation. Also fretting and micro cracks were observed on one side of face end of outer ring.