Safran Helicopter Engines, upbeat about prospects for the near-term market, is on track to certify three new engines this year that will push its helicopter portfolio up to the 3,000-shp class.
The French engine maker is showcasing those engines, along with its in-service products, at its booth (C4743) at Heli-Expo. These include the new 1,100- to 1,300-shp Arrano; Ardiden 3 covering the 1,700-2,000-shp range; and a mockup of the Aneto, which addresses the heavy helicopter market reaching up to 3,000 shp. The new engines will join Safran’s venerable Arriel 2, which has power range from 830 to 990 shp and is fitted on numerous models, on display.
Unveiled during the 2013 Heli-Expo, the Arrano is selected to power the new Airbus Helicopters H160. “We are currently maturing the engine, in both ground and flight tests, towards certification at the end of 2018,” said Bruno Bellanger, executive v-p programs of Safran Helicopter Engines.
The engine has accumulated more than 5,000 test hours, including more than 1,000 in flight. A third test H160 (PT3), equipped with a pre-production engine, flew in October. In 2017 the manufacturer delivered three pre-production engines, including those for PT3. “Everything is set for end-of-year engine type certification and delivery of the first production units,” added Bellanger.
Meanwhile, Safran’s Aneto, a higher power engine family unveiled this past October, has accumulated more than 450 test hours, including more than 50 in flight. Designed for new super-medium and heavy helicopters, a family of Aneto engines is planned, ranging from 2,500 to more than 3,000 shp output.
Italy’s Leonardo Helicopters has selected the first 2,500-shp model, the Aneto-1K, to power its twin-engine AW189K. While the engine was revealed in October, first flight of the Aneto-1K-powered AW189K took place in March 2017. EASA certification of the engine is planned for the end of 2018. According to Safran, Aneto brings significant benefits such as 25 percent greater power than existing engines of the same volume. Safran says the Aneto will deliver up to 15 percent better fuel economy than today's similar engine models.
Last year was key for the Ardiden 3 with EASA certification of the 3G (intended for the Ka-62) in June. The Ardiden 3C (for Avicopter’s AC352) should be EASA certified in upcoming months. Under the WZ16 designation, the Ardiden 3C will be certified by China’s CAAC in 2019. Both models have accumulated more than 10,000 hours of ground tests. “In parallel, we fully support flight tests conducted by Avicopter and Russian Helicopters,” Bellanger said, adding, “Ardiden 3 engines deliver at least 10 percent better fuel consumption over current engines in the same power range.”
Positive Outlook
Safran Helicopter Engines remains confident for the near future: “After the turbulence, we see a slow recovery of our markets in 2018 that will continue to 2020,” Bellanger said. “In 2017, the company remained resilient to the crisis affecting the helicopter sector, and committed to its strategy of preparing for the future.”
Last year, the helicopter market remained soft but stable. In 2017 Safran Helicopter Engines produced 732 new engines, roughly the same as in 2016. Production remained steady thanks to the resilience of the light and medium helicopter market (Arrius and Arriel). The company delivered a record 110 Arrius 2B2/2B2Plus (the H135 engine). The Bell 505 also entered service with the Arriel 2R in March 2017.
Its MRO activity also remained steady in 2017. According to Bellanger, the lowest point in the oil-and-gas market “is now behind us,” and he sees a small increase in flight hours from some operators of Safran-powered rotorcraft. Flight activity increases are mainly driven by Arrius and Arriel-powered helicopters.
The manufacturer continues to invest on its modernization program. In 2015, Safran Helicopter Engines started the construction of a new services and support facility in Tarnos (in the south of France). It has invested €50 million (USD$61.25 million) and the opening is anticipated in late 2018 or in the beginning of 2019. The facility initially will span 33,000 sq m (355,000 sq ft). But a second stage of construction is planned for 2020 that will expand the total space 77,000 sq m (829,000 sq ft). “The new facility will enable us to cut repair times in half,” Bellanger said.
Safran Helicopter Engines invests a significant share of its revenue—approximately 15 percent—in research and development. One major goal is to reduce the cost of ownership more specifically by improving fuel consumption. To achieve this, Safran is looking to improve its architecture, focusing particularly on a new compressor offering very high compression rates.
The company is also making innovations in the materials used in gas turbines, which will result in lighter, more robust engines that are easy to manufacture. This includes expansion of additive manufacturing (3D printing), which is already used in serial-producing components for the Arrano (fuel injector nozzles) and Ardiden 3 (combustors swirlers). The company estimates that, within five to 10 years, 30 percent of a complete engine could be manufactured using 3D-printing technology. Safran also is exploring the hybridization of thermal and electrical power sources.