Committed to the missionMilitary engine programs

Leading engine manufacturer

MTU Aero Engines is Germany’s leading engine manufacturer and a key player in the industry both in Germany and on an international level. The company designs, develops, manufactures, markets and supports commercial and military propulsion systems and industrial gas turbines, and offers full system capability in engine con-struction. In close cooperation with the world’s leading engine manufacturers as well as part-ners from industry and research, MTU is devel-oping the innovative propulsion systems of the future. It participates in advanced technology programs, providing valuable impetus with its developments. MTU’s low-pressure turbines, low-pressure compressors, high-pressure com-pressors and control systems are some of the best in the world. Its manufacturing processes, repair techniques and comprehensive service offerings are some of the best the global market has to offer. MTU’s expertise has a long history, the company’s roots date back to the early days of powered aviation. For more than 80 years now, the military business has formed the basis of the company’s system capabilities. Over the decades, MTU has repeatedly set technological benchmarks to drive forward the development of aviation, initially for military aircraft and later for the commercial sector too. Thanks to its experience, expertise and innovative strength, the company has carved out a position for itself as a technology leader in key areas and has established itself as a must-have partner.

Strong and capable partnerInnovative, capable and reliable—with its first-class technologies, products and services, MTU ensures that military customers can count on the full availability of their fleets at all times. It is the leading industrial company for practically all engines operated by the German Armed Forces and plays a key role in major European military engine programs. Mutual trust, proximity to the customer, reliability and expertise: these are the foundations for a successful engine partnership in the military arena. Together with its customers, MTU works to develop and implement tailored service support concepts to meet individual re-quirements quickly and reliably. MTU’s compre-hensive support services throughout an engine’s lifecycle—from development and manufacture, customized maintenance, facility and training concepts, right up to the provision of technical documentation and on-site support—enable part-ners such as the German Armed Forces to secure valuable know-how in their own ranks. This ap-proach has proven highly successful worldwide.

Full system competenceAlongside the development and manufacture 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.

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World-class technology

requirements and strategic considerations. Thanks to its extensive technology portfolio, MTU can also supply components across all phases of the engine life cycle.

Technologies for the engines of tomorrowMTU has identified various future technologies for the next generation of engines and will con-tinue to develop them. These include multidis-ciplinary processes and simulations used for the design of the engine concept and with com-ponents, for example the digital twin. New pro-duction processes such as additive manufactur-ing and the incorporation of bionic design enable new designs and structures. Enhanced engine sensor technology together with data evaluation methods improves analysis and forecasting in ongoing operations. New designs and innovative materials such as fiber-reinforced ceramics reduce the weight and also allow for higher engine temperatures. In the field of mainte-nance, augmented reality methods significantly enhance process validation and also help reduce costs.

Innovative support: The use of augmented reality (AR) technology in the future will accelerate maintenance and repair processes.

MTU Aero Engines is one of the world’s leading development partners and contributes its exper-tise to newly developed propulsion systems, such as the T408 powering the CH-53K heavy-lift helicopter and the TP400-D6 for the A400M military transport aircraft, while also specializing in models that have been in service for many years, such as the RB199 engine for the Tornado, the EJ200 engine for the Eurofighter Typhoon and the MTR390 engine for the Tiger. MTU’s broad experience forms a solid basis of unique expertise for the new and further development of advanced engine components and the asso-ciated control systems.

Strong in technology developmentMTU files more than 400 patent applications and makes 200 invention disclosure reports every year—a testament to the company’s innovative capabilities, which are also the result of a com-prehensive technological process that the com-pany uses to implement commercial and military innovations on time and within budget. This pro-cess systematically focuses on future product

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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 Eurofighter Typhoon and for the TP400-D6 engine that powers the A400M military transporter.

Award-winning turbines MTU has carved out a world-class technological position for itself in the commercial sector in the field of low-pressure turbines. An excellent exam-ple of this is its high-speed low-pressure turbine that operates at maximum efficiency. This exper-tise can also be extended to the military sector. For engines to operate even more efficiently, temperatures must be increased. This in turn

calls for new materials, which undergo extensive testing in a technology demonstrator. The basis for this engine demonstrator is an MTR390.

Advanced control systems When it comes to control systems, MTU can draw on valuable experience gained from the EJ200 engine as well as know-how from other military programs and the commercial sector. The real- time monitoring systems we use in this sector with their analysis and forecast capacities allow us to detect damage early on and to prevent it.

Assembly of a low-pressure compressor for the EJ200: MTU developed the low-pressure and high-pressure compressors as well as the electronic control unit, and manufactures these components for all Eurofighter Typhoon engines.

The company’s broad experience and exclusive know-how form a solid basis for the development and refinement of advanced control systems.

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A prime example of MTU’s manufacturing expertise are its compressors in blisk design for

the EJ200 engine that powers the Eurofighter Typhoon.

State-of-the-art production Engines used in military operations are subjected to extremely high stresses that vary greatly with the respective missions and operating environ-ments. For this reason, MTU develops special production processes for such highly stressed components, which it optimizes continuously.

Blisk technology Rotors featuring a blisk (blade integrated disk) 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.

One of these is selective laser melting, which helps produce complex components almost with-out the need for conventional tooling. Further advantages afforded by additive processes are markedly greater freedom of design, shorter pro-duction times, faster innovation cycles, lighter components with added functionality and lower development costs. MTU has achieved a break-through in engine production: having introduced additive processes to its operations in 2013, it is one of the first companies to manufacture components using such methods on an indus-trial scale.

MTU developed not only the PECM process for the manufacture of nickel blisks, but the machines as well—currently in operation in Munich.

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Intelligent maintenance solutions

MTU Aero Engines offers its military customers comprehensive support. In addition to conven-tional engine maintenance and smart repairs, customers benefit from a wide range of services that are tailored to satisfy its military partners’ specific needs.

Innovative repairs increase availabilityInnovative repair techniques optimize engine availability and reduce costs. Based on many years of experience and a fully integrated devel-opment process, MTU is continuously building on its high-tech repairs so that lifecycle costs continue to decrease. Examples of its compre-hensive repair expertise include adaptive milling to restore damaged compressor blade tips and innovative coating methods for protecting com-pressor airfoils from erosion.

Smart maintenance concepts Using engine health monitoring, extensive moni-toring of various engine parameters, and analyz-ing the condition of the engine based on this data, MTU experts can detect unusual operating conditions and identify countermeasures before the problem even occurs. As the next logical step, MTU plans to develop smarter analysis models based on a higher sensor density, which will perfect the process. This will enable opera-tors to schedule maintenance before an incident results in unplanned downtime, thus increasing availability of their weapon system. In addition, the use of augmented reality (AR) technology in the future will accelerate maintenance and repair processes.

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

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Comprehensive serviceGoing by the motto “Committed to the mission”, MTU Aero Engines aims to satisfy all of its mili-tary 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 mainte-nance 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 requirements, and thus provide the all-round support they need to ensure smooth operations.

Two strong partners MTU’s collaboration with the German Armed Forces is a prime example of its ability to devel-op and implement service concepts tailored to customers’ specific needs. MTU supports a large share of Germany’s propulsion systems and in 2002 it was the first company to successfully establish a cooperation of this kind with the German Armed Forces. Since 2014, work on the EJ200, RB199 and MTR390 programs has been performed under the same roof in Erding, Bavaria. MTU experts and specialists from the German Air Force work shoulder to shoulder to maintain

the military propulsion systems. The combi-nation of MTU’s technical expertise and the military’s operational experience ensures highly industrialized and cost-effective maintenance operations. Involving military personnel in the maintenance and repair work, in quality assur-ance management, logistics and in service sup-port in this way secures the assessment skills and technical abilities of the German Air Force and Army long term. The cooperation will be further expanded, the ultimate goal being to ensure full availability of the engines operated by the German Armed Forces at all times.

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

Another example of MTU’s comprehensive repair expertise is adaptive milling to restore damaged compressor blade tips.

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Power for the military

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

MTU Aero Engines is one of the world’s leading industrial system partners for the military engines that power combat jets, helicopters and military transport aircraft. Propulsion technology for mili-tary aircraft is geared toward maximum availabil-ity and long on-wing times. Where helicopter engines are concerned, MTU applies its expertise with advanced turboshaft engines and makes a valuable contribution to U.S. programs with its development activities. The company moreover provides powerful propulsion solutions for mili-tary transport aircraft that are required to carry

high payloads over long distances. Development and production of military engines calls for the combined expertise of several highly specialized companies, including MTU. Each bringing their specialist skills to the table, the participating part-ners join forces to ensure the overall success of the engine program. At a European level, MTU cooperates with all of the leading players in the industry and contributes its technological exper-tise to provide first-class products and services, as can be seen from the following examples:

MTU delivers excellent performance, now and in the future.

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

Low-pressure

compressor

Inter-mediate-pressure

compressor

High-pressure

compressor

Combustionchamber

High-pressureturbine

Inter-mediate-pressureturbine

Low-pressure/

powerturbine

Thrustreverser

Casing Gearbox Enginecontrol/

monitoring

Mainte-nance,

repair andoverhaul

Fighter Aircraft

EJ200

F110

F414

Larzac 04

RB199

Helicopters T408

MTR390

T64

Transport Aircraft

TP400-D6

Tyne

MTU Aero Engines’ component know-how

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EJ200 for the Eurofighter TyphoonA two-shaft turbofan engine with an afterburner, the EJ200 is built by EUROJET Turbo GmbH, a consortium with MTU, Rolls-Royce, Avio Aero and ITP Aero as stakeholders. The engine pow-ers the Eurofighter Typhoon. MTU developed the low- pressure and high-pressure compressors as well as the electronic control unit, and manufac-tures these components for all EJ200 engines. In addition, the company is responsible for assem-bly, testing and repair of all engines operated by the German Armed Forces and the Austrian Armed Forces.

TP400-D6 for the A400M military transport aircraftThe TP400-D6 for the A400M military airlifter is the most powerful turboprop engine of the West-ern world. It is developed and built jointly by MTU, Safran Aircraft Engines, Rolls-Royce and ITP Aero. MTU is responsible for manufacturing and main-taining the TP400-D6’s intermediate-pressure compressor, turbine and shaft and has a stake in several accessories. Furthermore, final assembly of all TP400-D6 production engines and mainte-nance work for the German Armed Forces takes place at MTU Aero Engines in Munich and accept-ance testing takes place on the test stand at MTU Maintenance Berlin-Brandenburg.

MTR390 for the Tiger combat helicopterDeveloped in cooperation with Safran Helicopter Engines and Rolls-Royce, the MTR390 is a turbo-shaft engine featuring a free power turbine. It powers the Tiger support helicopter co-devel-oped by France and Germany. MTU’s workshare comprises the core engine—the combustor and gas generator turbine—and some of the engine accessories. In collaboration with ITP Aero, MTU has developed an upgraded version of the engine (the MTR390-E) that delivers 14 percent more power. All production engines are assembled at MTU.

Partner of the U.S. militaryAs a risk-and-revenue-sharing partner of GE Aviation, MTU holds stakes in the F414, F110 and T408 programs. MTU’s workshare in the T408 for the CH-53K heavy-lift helicopter, the latest model in the CH-53 series produced by Lockheed Martin/Sikorsky, marks another mile-stone in its collaboration with its U.S. partner. MTU develops and manufactures the power tur-bine—the first time it has full responsibility for an entire module in a U.S. military engine program. Compared to its predecessor, the T64, the T408 is 1.7 times more powerful and delivers an 18 percent reduction in specific fuel consumption.

Full command of complex systems: Assembly work on the TP400-D6 for the A400M military transport aircraft.

MTU is responsible for the development and manufacture of the power turbine and will obtain licenses for mainte-nance, final assembly and testing of the T408 models to power a future European heavy-lift helicopter.1

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First-class quality for safe operations

The products and services that MTU Aero Engines deliver fulfil the highest standards of quality and reliability to which certifications and approvals from major worldwide airworthiness authorities testify. To ensure such high quality standards are maintained, the company places particular emphasis on continuous improvement in its en-gine development, production and maintenance activities. All products and processes are contin-uously monitored and subjected to regular inter-nal audits to identify and leverage all improve-ment potential—a strength from which all those involved benefit. The success of any company is contingent on the expertise and commitment of its workforce. MTU’s employees are highly motivated and highly qualified specialists in their fields. Dedicated young professionals work along-side seasoned experts, all invaluable assets to the company. Training and development of its employees’ professional and personal skills are high on the agenda at MTU. In this way, MTU makes sure its workforce remains highly quali-fied and internalizes the exacting quality stand-ards stipulated by the company and its military partners—putting them into practice in day-to-day operations and continually developing them. First-class quality management ensures consis-tently high quality standards across all parts and modules. MTU holds the following approvals authorizing the company to develop, manufac-ture and repair airworthy engine components and modules.

Certifications• ISO 9001:2015• ISO 14001:2004• EN 9100:2018• BS OHSAS 18001:2007• EMAS Approvals• Certificate of approval as a Contractor for

German Armed Forces Aeronautical Equipment as per A1-1525/0-8901

• Design organization approval as per EASA Part 21J

• Production organization approval as per EASA Part 21G

• Maintenance organization approval as per EASA Part 145

• Maintenance organization approval as per CFR 145

• Maintenance organization approval as per CAR 573

• Maintenance organization approval as per CAR 145

• Maintenance organization approval as per CCAR 145

• Maintenance organization approval as per DEMAR 145

• Authorized Economic Operator (AEO)

International specifications• Preparation of technical documentation

as per ASD S1000D• Material management as per ASD S2000M

Highly qualified and motivated: MTU employeeshave internalized the high quality requirements.

Under scrutiny: the human eye is and remains animportant instrument for quality assurance.

No compromises: Delivering consistently highquality has top priority at MTU.

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Full power ahead

With its broad portfolio of products and main-tenance services for commercial and military engines, MTU Aero Engines is in an excellent posi-tion for the future. As a well-established player in the industry, the company has secured stakes in major next-generation engine programs—for example in Pratt & Whitney’s GTF™ Engine Family of energy efficient GTF™ engines. MTU’s work-share in these engines includes components for the high-pressure compressor and the high-speed low-pressure turbine.

Committed to mission successMTU is also well positioned for the future in its military business. The process to procure a new heavy lift helicopter for the German Armed Forces is underway. Lockheed Martin subsidiary Sikorsky Aircraft has entered a bid for the contract with its CH-53K King Stallion powered by GE Aviation’s T408 engine. The team of German industry part-ners also includes MTU, which supplies the power turbine and repair work in Germany for this powerful engine.

Working in partnership with Safran Aircraft Engines, MTU will develop, manufacture and support the engine to power Europe’s Next Generation Fighter (NGF). This engine, known as the Next European Fighter Engine (NEFE), will shape Europe’s military engine business for decades to come. As part of this partnership, MTU will contribute its flagship high-pressure and low- pressure compressors. It will also take respon sibility for the low-pressure turbine and control systems and provide maintenance and support from development to operation.

Thanks to its many years of experience in the military business, its technological expertise and its know-how in supporting engines across their entire lifecycle, MTU is well positioned to find and implement the best solution for its military cus-tomers. MTU continues to prove itself as a relia-ble partner to the military—now and in the future.

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

The requirements for a next-genera-tion fighter aircraft have been clearly defined, among them increased sur-vivability, maximum range and high mission flexibility.

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MTU Aero Engines AGDachauer Straße 66580995 Munich • GermanyPhone +49 89 1489-0Fax +49 89 1489-5500info@mtu.dewww.mtu.de