The United Engine Corporation (UEC), a subsidiary of the Rostec State Corporation, has successfully concluded another significant phase of engineering tests for the new PD-8 aircraft engine, designed for the Russian regional airliner Superjet 100 (SJ-100). The tests for fan blade failure were carried out at the UEC-Saturn test stand in Rybinsk and represented a significant milestone in the certification process of the engine, which is essential for the aircraft’s commercial operation.
During a period when the Russian aviation sector concentrates on complete import substitution of components for passenger aircraft, the development of a domestic engine has emerged as a strategic priority. The SaM146 engine used to power earlier Superjets can no longer be fully deployed due to the withdrawal of foreign partners from the program, thereby markedly heightening the urgency of implementing a completely Russian powerplant.
The Significance of Fan Blade-Off Testing: Ensuring Safety and Certification
Engineering tests that simulate the failure of a fan blade are among the most essential evaluations in the certification process of any aircraft engine. The objective of these tests is to verify that, in the event of a fan blade failure during take off power operation, the engine casing remains intact and is not compromised. A casing rupture could compromise the integrity of the aircraft fuselage and result in a calamitous in-flight event.
At the Rybinsk test facility, the test was conducted using a pyrotechnic charge positioned directly within one of the fan blades. Following the application of take off power to the engine, the charge was ignited, resulting in the failure of the blade. Despite the substantial energy discharged during the incident, the PD-8’s structure remained intact with all fragments retained, and no breach of the engine casing was observed. This verifies that debris remained within the containment system, fulfilling a mandatory criterion for operational safety certification.
Such bench exams constitute an official component of the certification process and are essential for demonstrating adherence to aviation regulatory standards. Only upon the successful completion of the entire test cycle, including rigorous failure simulations, can the final Type Certificate be granted, thereby permitting the engine to commence commercial operation.
Test Preparation and Additional Monitoring Systems
Preparation for the test entailed a multi-phase procedure and necessitated the installation of supplementary equipment at the UEC-Saturn test stand. This comprised a slip ring assembly, a phase synchronization system, and an air sampling system, which are essential for evaluating environmental conditions and cabin safety parameters in the event of internal engine damage.
The air monitoring system verified that oil vapor emissions into the aircraft’s air conditioning system after the blade failure remained within acceptable limits. This outcome indicates that the engine’s safeguarding systems operate effectively even in the event of severe failure scenarios, ensuring not only mechanical integrity but also the safety of passengers and the proper functioning of life-support systems.
The test results further validated that the engineering solutions deployed in the PD-8 adhere to the specifications outlined in the technical requirements. The engine design demonstrated the ability to withstand severe dynamic loading, while its monitoring and safety systems functioned reliably throughout the testing process.
Previous and Complementary PD-8 Tests
Before conducting the fan blade-off test, the PD-8 underwent a series of additional engineering assessments at the UEC-Saturn open test stand. These comprised acoustic evaluations designed to assess noise and vibration levels produced during engine operation.
Water ingestion experiments were also carried out, replicating heavy rainfall and accumulated standing water on runways during takeoff and landing. These experiments demonstrated that the engine sustains safe and stable operation even under substantial water loads.
Additional tests assessed engine performance in crosswind conditions and confirmed the functionality of the thrust reverser system employed to decelerate the aircraft following landing. All primary tests were performed at thrust levels surpassing 8,000 kilogram-force, verifying that the engine fulfills the performance specifications for short-haul aircraft such as the Superjet 100 and amphibious aircraft like the Be-200.
Integration into Flight Testing and Certification of the SJ-100
In addition to stationary laboratory tests, the PD-8 has been subjected to a series of engineering and flight assessments as part of its evaluation as a flying test platform. These covered experiments were conducted aboard the Il-76LL flying laboratory as well as the experimental Superjet aircraft. The program accrued over 4,000 operating hours, a significant metric reflecting long-term engine reliability and performance under actual flight conditions.
One of the most notable milestones was the inaugural complete flight of the SJ-100 fitted with domestically produced PD-8 engines, carried out in March 2025. The aircraft sustained flight for approximately forty minutes, attained velocities of up to 500 kilometers per hour, and ascended to an altitude of approximately 3,000 meters. This flight was conducted as part of the official certification program and successfully demonstrated the integration of the engine with the aircraft.
According to industry representatives, the full certification procedure, covering ground and flight testing, is scheduled for completion by the end of 2025. Serial production and installation of engines on the SJ-100 aircraft are anticipated to commence in the first half of 2026.
Simultaneously, the Russian government and industrial enterprises are diligently monitoring not only the powerplant but also the comprehensive localization of the aircraft, encompassing avionics, landing gear, and air-conditioning systems, thereby converting the SJ-100 into a wholly domestic product.
Industrial Importance and Production Forecast
The development of the PD-8 project commenced in 2019, and its progress plainly reflects the technological foundation laid during the development of the more advanced PD-14 engine for the MC-21 aircraft. The adoption of contemporary domestic materials and cutting-edge engineering solutions facilitated the program’s success while substantially shortening development timelines, which generally span from ten to twelve years for a new aircraft engine.
In addition to the UEC-Saturn facility in Rybinsk, other enterprises are increasing their production capacities to support the fabrication of PD-8. Facilities in Perm are currently being modernized, which will enable the production of components for up to 200 engines annually in the future.
Conclusion: PD-8 as a Progress Toward Technological Autonomy
The successful completion of rigorous tests, including the fan blade-off simulation and various other extreme assessments, signifies not only a technical milestone but also an important step toward securing the PD-8 Type Certificate necessary for the commercial operation of the SJ-100. This improvement underscores the Russian aviation industry’s dedication to technological self-sufficiency and the development of competitive domestic products.
Despite ongoing certification activities and the inherent complexities of large-scale aviation initiatives, the PD-8 project exhibits considerable progress in the development of Russian aircraft powerplants and signifies a notable milestone in the nation’s civil aviation strategy.