Russian aircraft engine manufacturers announced on February 12, 2026, the end of extensive experimental design work and the beginning of serial production of improved structural elements for the mass-produced PS-90A aircraft engine and its PS-90A-76 modification. This development is an important achievement for the domestic aviation engine industry, as these powerplants continue to be used in both commercial and military transport aircraft throughout Russia.
Russian wide-body and transport aircraft, including the Tu-204, Tu-214, Il-96-300, and modernized Il-76, are often equipped with these engines. The modernization of these aircraft contributes to their overall performance by increasing their durability and operational reliability, thereby extending their service life.
The PS-90A Engine’s Historical Significance
The PS-90A is a high-bypass turbofan engine that was developed in the late Soviet era to accommodate the changing requirements of the civil aviation sector in Russia. It was an enormous leap forward in comparison to the Soviet engines that preceded it, as it resulted in increased fuel efficiency, reduced emissions, and enhanced compliance with international aviation standards.
Serial production commenced in the 1990s at manufacturing facilities in Perm, which is one of the most significant centers for aircraft engine design and production in Russia. The PS-90A evolved into the mainstay of Russia’s medium- and long-haul aviation fleet.
The wide-body Il-96-300 passenger jet, the Tu-204 and Tu-214 families of engine-powered aircraft, and later variants of the Il-76 transport aircraft. In comparison to previous generations, it enabled airlines and operators to satisfy more stringent environmental requirements while achieving superior economic performance.
PS-90A-76—A Transport Aviation Workhorse
One of the most important members of the PS-90 family is the PS-90A-76, a modification that has been specifically designed to accommodate heavy military transport aircraft, such as the Il-76.
This version was intended to replace the older D-30KP engines, which had been reliable for decades but no longer met the modern standards for operational safety, efficiency, and emissions.
The PS-90A-76 was installed on the Il-76, which resulted in improved fuel economy, enhanced environmental performance, and greater operational reliability. These factors are particularly important for aircraft that operate on lengthy routes and in demanding logistical missions.
Wear Issues and the Need for Modernization
One of the most critical subsystems, the mounting system for the combustion chamber fuel manifolds, was found to have predictable degradation over the course of years of large-scale operation of PS-90A engines and their variants.
This assembly is subjected to dynamic loads, thermal stress, and intense vibration. The mating surfaces of brackets, spherical bushings, and support cushions underwent faster wear over time, resulting in the formation of critical gaps.
The kinematic chain’s emergence of play resulted in an increase in vibration loads that were transmitted to the fuel conduits. This, in turn, could have negatively impacted engine stability during long-term operation.
The identification of this vulnerability led to a comprehensive research and engineering undertaking that was designed to eliminate the weak point in the engine’s structure. The improved design was developed under the leadership of specialists from UEC-Perm Motors and UEC-Aviadvigatel.
Engineering Breakthrough: Eliminating Traditional Hinges
The experimental design work yielded the most noteworthy result: a fuel manifold mounting structure that is fundamentally new and drastically distinct from conventional engineering solutions.
The core idea of the modernization was the complete absence of the movable joints that are typical of classical hinge systems.
Instead, engineers devised a system that used fastening elements that covered linear segments of metallic cable. This solution is described as an all-metal vibration-isolating system that relies on dry friction.
Designers were able to drastically decrease the transmission of vibration loads to the fuel lines and other sensitive engine parts, eliminate the formation of mechanical play, and reduce wear between components by leveraging dry friction and removing hinge mechanisms.
The innovation improves long-term operational stability, reduces the likelihood of mechanical failure, and extends the lifetime of components without necessitating frequent maintenance.
Real-World Application and Serial Production
The upgraded design was granted approval and subsequently introduced into serial production after the testing cycle was completed. This implies that the components are currently being produced on an industrial scale and are prepared for use during routine maintenance and servicing procedures for PS-90A and PS-90A-76 engines.
One of the main advantages of the modernization process is that the enhanced mounting assemblies can be installed in engines that are currently in service, as well as in those that are currently being built. This capability substantially reduces operational risks and assists operators in managing long-term maintenance expenses.
The granting of a patent has officially confirmed the technical innovation of the solution, emphasizing its originality and technological contribution to the advancement of aircraft engine engineering.
Industry Awards and Recognition
The P. A. Solovyov Award, a prestigious achievement in the field of aviation and engine design, was bestowed upon the novel engineering solution, which has garnered substantial praise from industry experts.
The award is given in recognition of exceptional accomplishments in technological innovation and experimental engineering, emphasizing advancements that have a substantial influence on the aerospace industry.
The newly developed assembly’s technical sophistication and its broader significance to the domestic aviation industry are underscored by this recognition. The PS-90 family’s modernization serves as an illustration of the exceptional expertise that Russian engineers possess, particularly when confronted with intricate mechanical challenges.
Russian Aviation’s Strategic Significance
The introduction of upgraded structural elements for the PS-90A and PS-90A-76 is not just a routine technical improvement; instead, it has strategic implications.
Initially, it improves the operational reliability of critical powerplants that provide support to a significant portion of Russia’s commercial and transport aviation fleet.
Secondly, the upgrade directly enhances the economic efficacy of aircraft operations by reducing the overall volume of required servicing and extending maintenance intervals.
Third, the installation of the new components during overhaul procedures will extend the tenure of existing engines, which is particularly advantageous for aircraft that operate in challenging environments and harsh climates.
In conclusion,
The experimental design work for the PS-90A and PS-90A-76 engines, which finished on February 12, 2026, is a significant advancement in the development of Russia’s aircraft engine industry.
The successful implementation of an innovative fuel manifold mounting structure, which includes the elimination of moving joints and the implementation of dry-friction vibration isolation, is expected to improve the stability, extend the service life, and improve the reliability of powerplants that are the backbone of many Russian aircraft.
Simultaneously, the project underscores the nation’s commitment to technological self-reliance in a global aerospace market that is becoming increasingly competitive, while also reflecting the ongoing development of domestic engineering capabilities.