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Ivchenko-Progress

Ivchenko-Progress, officially the "Zaporizhzhia Machine-Building Design Bureau 'Progress' named after Academician O. G. Ivchenko," is a enterprise specializing in the design, manufacture, testing, certification, and support of engines, including turbofans, turboprops, engines, and propellers for , energy, and marine applications. Founded on May 5, 1945, in , , as a state design bureau (originally OKB-478), the company transitioned to joint-stock ownership on January 31, 2025, and operates as a of the state-owned Ukroboronprom concern. With approximately 3,000 specialists, Ivchenko-Progress has developed over 80 engine types and modifications that power 66 models operating in more than 100 countries, accumulating over 300 million flight hours and producing more than 80,000 units. The bureau's history traces back to the post-World War II era, when it was established to advance Soviet aviation engine technology under the leadership of figures like Alexander Ivchenko and later Vladimir Lotarev, evolving through mergers and renamings such as Ivchenko Lotarev . Key innovations include high-bypass engines like the D-18T, a three-spool design providing 229.5 kN of thrust that powers the and powered the unique An-225 Mriya cargo aircraft—destroyed in 2022—enabling their heavy-lift capabilities. Another milestone is the D-27 engine, a three-shaft, design delivering up to 14,000 shp for the transport, representing early advancements in fuel-efficient . The company has also produced the AI-222 series of s, such as the AI-222-25, for trainer and , with interest from international partners including . In recent years, Ivchenko-Progress has expanded into , notably collaborating with on the AI-35 for the Gezgin , fostering and joint production opportunities. These efforts underscore its role in global aerospace, despite challenges from geopolitical tensions affecting Ukraine's defense industry, including the destruction of key assets like the An-225 in 2022.

History

Founding and Soviet Era

Ivchenko-Progress traces its origins to 1945, when it was established as an experimental design bureau (OKB) at Plant No. 478 in , , under the leadership of aircraft engine designer Alexander G. Ivchenko. Initially focused on engines for post-World War II , the bureau developed models such as the AI-4 for the helicopter, supporting the Soviet Union's rebuilding of its aviation fleet amid wartime devastation. Ivchenko's expertise in engine design laid the groundwork for the organization's growth within the Soviet aviation industry. In the , the bureau transitioned to , marking a pivotal shift toward and technologies essential for modern military and civilian aircraft. By the 1960s, Ivchenko's team produced the AI-25 , a medium-bypass engine with 1,500 kgf , powering the transport and regional airliner, entering series production in 1962 and enabling efficient short-haul operations across the USSR. The 1970s brought further milestones, including the D-36 high-bypass , the Soviet Union's first three-shaft engine design delivering 6,500 kgf thrust, which powered the airliner and later /74 transports. Following Ivchenko's death in 1968, Vladimir Lotarev succeeded as chief designer. The bureau, renamed Machine-Building Design Bureau (ZMKB) Progress in 1966, integrated advanced expertise under Lotarev's leadership. This consolidation enhanced its capabilities, leading to over 30 engine types and modifications for fighters, transports, and helicopters by the late Soviet period. Throughout the Soviet era, Ivchenko-Progress played a central role in the national aviation sector, with production at associated facilities like Zaporozhye Motorworks scaling to thousands of units annually by the , supporting deployments in operations and across the . The bureau's innovations, driven by Ivchenko's foundational contributions until his passing, resulted in engines that have accumulated over 300 million operating hours in total, underscoring their reliability and impact.

Post-Soviet Developments

Following Ukraine's independence in December 1991, the Zaporizhzhia-based design bureau, formerly OKB-478, transitioned into a and was renamed the Ivchenko-Progress State Enterprise in 1994 to honor its founder, Oleksandr Ivchenko. This reorganization reflected a broader shift from the centralized Soviet to a market-driven, export-oriented model, as the company sought international partnerships to offset the loss of Soviet-era subsidies and orders. The 1990s brought severe economic challenges for Ukraine's aviation sector, including , funding cuts, and industrial contraction, which drastically reduced Ivchenko-Progress's output and forced workforce reductions. Recovery began in the early through strategic collaborations, notably a 2005 agreement with JSC granting the manufacturer access to design and operational documentation, enabling joint production and overhaul of engines like the D-18T series. This partnership helped restore manufacturing capacity and supported expansion into civilian applications, including the sustained production and repair of D-18T high-bypass turbofans for An-124 and An-225 freighters, with over 30 units refurbished by the mid-2010s to meet global logistics demands. Key milestones in the included international certifications to access Western markets, such as the European Aviation Safety Agency's (EASA) restricted type certification for the in 2009, facilitating its use in upgrades. The also advanced export-oriented developments, exemplified by the AI-222 family of low-bypass turbofans, initiated in the early and co-produced with for the L-15 advanced trainer, with afterburning variants like the AI-222-25F entering testing by 2007 to enable supersonic capabilities. By 2011, Ivchenko-Progress had established full-cycle production capabilities, encompassing design, testing, manufacturing, and certification under standards like ISO 9001 and EN 9100. Exports grew significantly through the early , with engines powering aircraft in over 100 countries and partnerships yielding contracts such as the supply of AI-222 variants to Asian manufacturers, contributing to the company's role in supply chains.

Recent Challenges and Adaptations

The in 2014 disrupted supply chains for Ukraine's industry, including Ivchenko-Progress, as it severed long-standing cooperative production ties with Russian partners and led to the loss of and components previously sourced from the region. This escalation strained the company's operations, forcing a toward diversification amid emerging geopolitical tensions. The full-scale in February 2022 intensified these challenges, with Ivchenko-Progress's facilities in facing direct threats from occupation attempts and frequent shelling in , placing the design bureau under constant risk of missile strikes. Despite production disruptions from the conflict, including temporary halts due to attacks on nearby infrastructure, the company maintained essential operations to support Ukraine's military, with employees continuing development under perilous conditions. sanctions imposed on further complicated maintenance for the D-18T engine used in Russian An-124 aircraft, as sought to indigenize upgrades without Ukrainian expertise, highlighting Ivchenko-Progress's critical role in legacy systems. To adapt, Ivchenko-Progress relocated key representatives and pursued international partnerships, enabling continued engine production such as the AI-322 turbofan for unmanned aerial vehicles, fulfilling orders for Turkish drones despite ongoing hostilities and sanctions pressures. In 2023, the company signed a memorandum with firm PBS Aerospace to co-develop the AI-PBS-350 small turbojet engine for cruise missiles and UAVs, demonstrating resilience through joint ventures amid supply constraints. By 2025, the AI-322F-powered Kızılelma drone was considered for potential roles in international advanced projects, including as an escort in initiatives. On January 31, 2025, Ivchenko-Progress transitioned to joint-stock ownership, operating as a of Ukroboronprom. Supply disruptions from the war prompted allies like to test domestic replacements for the AI-222 engine in programs such as the LOWUS stealth drone, addressing reliability concerns in international collaborations. Ivchenko-Progress sustained R&D and production critical to national defense despite workforce strains and infrastructural damage.

Organization and Facilities

Leadership and Structure

Ivchenko-Progress operates as a (JSC), originally established as a in 1990, transitioned to joint-stock ownership on January 31, 2025, and integrated into the State Concern "Ukroboronprom," Ukraine's primary defense industry conglomerate, which oversees military production and exports. The enterprise operates within the framework of Ukraine's defense industry policies, under the oversight of the of Strategic Industries through Ukroboronprom, focusing on design while adhering to national regulations in the post-Soviet era. The current leadership is directed by General Director Ihor Kravchenko, who has served in the role since the 2010s and holds a Doctor of Technical Sciences degree with expertise in engine design. This structure supports specialized oversight in technical development, though detailed board compositions including dedicated technical and commercial directors are managed internally to align with Ukroboronprom's reforms. Organizationally, Ivchenko-Progress centers on the Zaporizhzhia Machine-Building Design Bureau (ZMKB), its primary design division responsible for engine conceptualization and prototyping, complemented by integrated testing facilities for performance validation and units to ensure compliance with standards. Employee numbers have fluctuated due to external factors, but the enterprise maintains a dedicated to within Ukroboronprom's broader network. As of 2025, it employs approximately 3,000 specialists. Governance emphasizes and , with certifications including DSTU ISO 9001:2015, ISO 9001:2015 (No. UA228430), BS EN 9001:2015, and EN 9100, which align with for systems. As a key member of Ukroboronprom, Ivchenko-Progress contributes to the conglomerate's strategic goals, including and activities across over 50 countries.

Production Sites and Infrastructure

Ivchenko-Progress maintains its primary headquarters and production facilities in , , at 2 Ivanova Street. This site encompasses a comprehensive and experimental complex designed for the , , and testing of aircraft engines with capacities up to 40 tons. The supports advanced processes, including , prototyping, , and overhaul services for engines used in aviation applications. Serial production of Ivchenko-Progress engines is integrated with JSC, also based in , which handles large-scale manufacturing based on designs from the bureau. This collaboration enables the full lifecycle management of engine production, from initial development to final assembly and maintenance, ensuring compatibility with various platforms. The facilities include test benches for performance validation and component integration, contributing to the operational reliability of engines powering over 60 aircraft types worldwide. The infrastructure features specialized equipment for engine testing and assembly, allowing for the evaluation of propulsion systems under simulated operational conditions. Pre-war operations emphasized efficient production workflows, with historical output exceeding 80,000 engines across series plants. Since Russia's full-scale invasion in 2022, the facilities have encountered significant challenges due to their proximity to conflict zones, including damage from airstrikes. Notable incidents include a September 2024 strike targeting Ivchenko-Progress and adjacent plants, disrupting production and requiring repairs to maintain continuity. Despite these disruptions, the organization has sustained development and testing activities, adapting to wartime conditions to support Ukraine's defense needs.

Research and Development

Key Innovations

Ivchenko-Progress has pioneered several engineering breakthroughs in technology, focusing on efficiency, durability, and environmental performance across various engine architectures. A significant advancement lies in optimizing s to balance and consumption. The development of a 5.7:1 in the D-18T exemplifies this, enabling superior for heavy transport applications by directing a larger proportion of around the core, reducing specific consumption while maintaining high levels. Material innovations have also been central to the bureau's contributions, particularly in turbine component design to withstand extreme operating conditions. In the AI-450 turboprop, the adoption of single-crystal blades allows for sustained operation at temperatures up to 1,500°C, improving and extending component life through enhanced resistance and reduced oxidation. This represents a leap in high-temperature , minimizing the need for complex cooling systems and boosting overall engine reliability. Complementing these are advanced coatings and alloys, such as oxide dispersion strengthened titanium aluminides for and elements, which further lower fuel use by over 6% and increase power output by more than 15%. The bureau has embraced digital methodologies to accelerate design and optimization processes. Since the , implementation of CAD/CAM systems has streamlined complex geometries in engine components, reducing development cycles and manufacturing errors. Advanced dynamic modeling has been applied to prototype designs, with material innovations yielding 5-7% savings in fuel burn by refining airflow paths and combustion dynamics. These innovations have applications in both civilian and , enhancing operational versatility, including early Soviet propfan concepts from the 1980s such as the D-27, which explored unducted fan architectures for ultra-high efficiency.

International Collaborations

Ivchenko-Progress maintains a close partnership with Ukrainian manufacturer for engine production, serialization, and integration into aircraft platforms. This collaboration, formalized in a 2005 agreement, grants access to design and operational documentation from Ivchenko-Progress, facilitating joint efforts on and engines for both and applications. A key international venture involves Czech aerospace firm PBS Velká Bíteš, with whom Ivchenko-Progress signed a memorandum of understanding in June 2023 to jointly develop the AI-PBS-350 turbojet engine. Optimized for unmanned aerial vehicles and cruise missiles, the engine delivers 3.4 kN of thrust at a weight of 51 kg, with development progressing through 2024 and into 2025 to support single-mission UAV systems. Export agreements have expanded Ivchenko-Progress's reach, notably through the supply of AI-322 engines to for powering the Anka III stealth . Integration tests in 2025 demonstrated the engine's compatibility, enabling the to achieve speeds up to 425 knots while carrying guided munitions from internal bays. Ongoing collaborations with , facilitated by Ivchenko Progress India in partnership with , support the localization and supply of Ukrainian-designed engines for regional needs, building on ties established in the . In joint programs, Ivchenko-Progress has historical ties with for the An-70 medium-range transport aircraft, which utilizes four D-27 three-shaft engines developed by the bureau and producing 10,350 kW each for enhanced . More recently, as of 2025, discussions positioned Ukrainian engines for potential integration into drone components of the () initiative, involving Turkish firm to support systems. Post-2022 sanctions stemming from Russia's invasion of have restricted maintenance and parts supply for Russian operators of Ivchenko-Progress engines, disrupting legacy programs and prompting strategic diversification toward Asian and European markets. This shift has strengthened partnerships in and the while mitigating risks from halted collaborations, such as those with . Ivchenko-Progress engines power 64 types of operated in more than 100 countries, underscoring their global adoption in civilian and .

Engine Products

Turbojets and Early Engines

Ivchenko-Progress's early engine development, under the OKB-478 banner established in , primarily focused on piston engines for post-World War II Soviet needs, particularly in helicopters and light . The AI-26 series represented one of the bureau's initial successes, with the AI-26V variant—a nine-cylinder air-cooled radial piston —delivering 575 hp and serving as the powerplant for the , the Soviet Union's first mass-produced introduced in 1948. This featured a robust design suited for rugged operations, contributing to the Mi-1's role in utility and training missions across Soviet and allied forces. Another key early piston engine was the AI-14, a nine-cylinder radial design initiated in , producing 225-300 hp depending on the variant, and optimized for such as the trainer. The AI-14's air-cooled configuration and reliable performance made it a staple for aerobatic and basic , with production spanning decades and exceeding 10,000 units to support widespread Soviet exports during the early period, including to nations involved in conflicts like the . These engines emphasized simplicity and maintainability, evolving from pre-war radial designs while incorporating improvements in supercharging for higher-altitude performance. Venturing into turbojet technology in the early 1950s, OKB-478 developed the AI-7, a compact single-shaft engine rated at 70 kgf (686 N) of . Intended for experimental applications, the AI-7 powered the V-7 project, where engines were mounted at the rotor blade tips to augment lift via ramjet-assisted propulsion, showcasing innovative but short-lived tip-jet concepts for vertical flight. With an and annular , the AI-7 achieved a of approximately 5:1, typical for small turbojets of the era, though production remained limited to prototypes due to the technology's niche role. Overall, Ivchenko's engines like the AI-26 and AI-14 saw extensive —part of a broader output exceeding 80,000 and units historically—and played a vital part in equipping Soviet exports for training and support roles in the and . By the , these early designs were largely retired in favor of more efficient variants, marking the bureau's shift toward turbofans for broader applications.

Turbofans and High-Bypass Variants

Ivchenko-Progress began developing engines in the , evolving from earlier designs to incorporate bypass fans for improved and performance in and applications. The AI-25, a low-bypass twin-shaft , was one of the early models, entering series production in 1970 with a takeoff of approximately 16.9 . It powers aircraft such as the and An-32 short-haul transports, providing reliable propulsion for regional operations with a specific consumption of 0.58-0.6 kg/(kgf·h) in . A key high-bypass example is the D-18T, a three-shaft developed starting in 1972 and certified for the An-124 and An-225 heavy-lift freighters. This engine delivers 229 kN of takeoff at a of 5.7:1, enabling exceptional payload capacity while maintaining a specific consumption of 0.345-0.362 kg/(kgf·h) at takeoff. Over 188 units have been produced, supporting strategic missions. The AI-222 family represents medium-bypass advancements from the , with variants like the AI-222-25 offering 24.7 kN dry thrust and up to 41.2 kN with at a of 1.19:1. Designed for advanced trainers such as the , it achieves a specific of around 0.64 kg/(kgf·h) and a high exceeding 5.6. These engines emphasize scalability through modular core designs, allowing adaptation across thrust classes for both civilian and military uses. Later variants incorporate full authority digital engine control () systems introduced in the 2000s, enhancing reliability and performance optimization, as seen in related models like the AI-225 derivative. Ongoing upgrades, such as the D-18T Series 3M, focus on emissions reduction and noise compliance to ICAO Chapter 4 standards, extending hot-section life to 14,000 hours while meeting modern environmental requirements.

Turboprops and Turboshafts

Ivchenko-Progress has contributed to the development of engines for regional and , with the AI-450 series representing a modern design for such applications. The AI-450S , a two-shaft with a and free power , delivers a takeoff power of 340 kW (456 shp) and is intended for powering general-purpose and trainers. The AI-450T variant powers unmanned systems such as the Akıncı , enabling extended endurance in missions, including configurations. This features a allowing conversion between and modes, with composite materials in propeller blades contributing to a 10% weight reduction compared to earlier metal designs, enhancing efficiency for low-speed operations. Turning to turboshafts, Ivchenko-Progress collaborates on the TV3-117 family, inherited through mergers with Lotarev design elements and jointly developed with and , powering combat helicopters like the Mi-24. The TV3-117V series offers 1,640 kW (2,200 shp) takeoff power, with a free power turbine configuration and an 18:1 reduction gear ratio to drive the rotor at optimal speeds. Post-merger adaptations include enhanced variants like the TV3-117VMA-SBM1V, achieving up to 2,059 kW (2,760 shp) in emergency ratings while maintaining reliability for Ukrainian and export helicopter fleets. Serial production of TV3-117 engines at exceeded 100 units annually before 2022, supporting widespread applications in Mi-8/17/24 series helicopters for both and uses. These engines incorporate features like composite fan blades for reduced weight and improved durability, with power ratings scaling to 2,237 kW (3,000 shp) in select high-output variants for heavier demands. Although primarily shaft-output designs, some integrations draw on high-bypass technology from related programs to optimize in propeller-driven setups.

Propfans and Experimental Designs

Ivchenko-Progress has pioneered technology through the development of the , a three-shaft introduced in the for the . This drives the SV-27 unducted , a counter-rotating system featuring 14 blades arranged in two rows of 8 and 6, delivering an equivalent of approximately 13,240 equivalent horsepower (ehp) with a specific fuel consumption of 0.180 kg/h/ehp. The design incorporates swept blades to maintain high at speeds, contributing to overall improvements in fuel economy compared to traditional turboprops. The counter-rotating configuration of the SV-27 reduces swirl losses in the airflow, enhancing thrust efficiency by recovering that would otherwise be wasted in single-rotation propellers. This approach, combined with the open rotor architecture, positions the D-27 as a hybrid between and engines, offering up to 15-20% lower specific fuel consumption than equivalent high-bypass turbofans in regional applications. Although serial production of the D-27 began, it has seen limited deployment due to the An-70 program's challenges, with only a handful of prototypes and test articles built. The AI-35 is a compact engine developed in collaboration with for the Gezgin , providing approximately 3.5 kN of . As of 2025, it supports joint and efforts. In experimental designs, Ivchenko-Progress has collaborated with Velká Bíteš on the AI-PBS-350 , a compact engine optimized for unmanned aerial systems (UAS) and , providing 350 daN (3.5 kN) of at a specific of 1.16 kg/daN·h. Weighing just 51 kg with a four-stage and single-stage turbine, it measures 246 mm in length and 292 mm in diameter. Serial began in 2025. This project emphasizes lightweight, high- solutions for single-mission UAVs, building on Ivchenko-Progress's expertise in small gas generators. Current efforts focus on green aviation, integrating low-emission combustion chambers into prototypes like the D-336 and AI-336, achieving levels of ≤50 mg/Nm³ and CO of ≤100 mg/Nm³—reductions of up to 30% compared to prior designs. These advancements support broader goals of 15-20% gains and lower , aligning and experimental engines with sustainable propulsion targets.

Applications and Legacy

Civilian Aviation Uses

Ivchenko-Progress engines have played a significant role in powering large commercial transport aircraft, particularly the and An-225 Mriya freighters, where the D-18T high-bypass enables exceptional capacities. The An-124, equipped with four D-18T engines each producing 229 kN of , achieves a maximum of 150 tonnes, supporting its use in oversized cargo operations across global logistics networks. The An-225 variant, with six D-18T engines, extends this capability to a maximum takeoff weight of 640 tonnes and payloads up to 250 tonnes, making it ideal for transporting outsized items like satellite components or heavy machinery. The sole An-225 was destroyed in February 2022 during the . These engines contribute to the aircraft's reliability, with total extensions through upgrades allowing up to 80,000 hours in modernized variants. In regional aviation, Ivchenko-Progress turbofans and turboprops power versatile like the and , enhancing short-haul and utility transport efficiency. The AI-24 turboprop, rated at 2,420 shp, powers the An-26 twin-turboprop transport, which has been operated by over 30 military and civilian entities worldwide, including airlines in , , and , for and services in remote areas. Similarly, the D-36 three-shaft on the Yak-42 provides 63.7 kN per engine, offering competitive specific fuel consumption of around 0.63 kg/(daN·h) in cruise, which supports economical operations on medium-range routes compared to earlier Soviet designs. Although direct comparisons to equivalents vary by mission profile, the D-36's design emphasizes balanced performance for regional fleets in challenging environments. Ivchenko-Progress engines hold a notable presence in (CIS) regional aviation, powering approximately 60 certified aircraft types operated in over 100 countries, reflecting broad international acceptance through certifications from bodies like the European Aviation Safety Agency (EASA) and the Interstate Aviation Committee. This includes auxiliary power units and variants integrated into civilian transports, via reliable maintenance and adaptability. The AI-450 , a modern development, offers up to 670 kW shaft power for utility roles in helicopters and potential conversions, though primary installations often pair with Western alternatives for certification flexibility. These engines have also supported humanitarian efforts in the 2020s, with An-124s delivering critical during global crises. For instance, in 2020, An-124 flights transported medical supplies from to amid the , carrying over 50 tonnes per mission. In 2023, similar operations airlifted more than 100 tonnes of relief to earthquake-affected areas in and , underscoring the D-18T's role in rapid-response logistics.

Military and Drone Applications

Ivchenko-Progress engines have played a significant role in , particularly in advanced trainers and unmanned aerial vehicles (UAVs), powering platforms used by multiple nations for combat training and missions. The AI-222-25 engine, developed by Ivchenko-Progress, equips the advanced jet trainer, which serves both and air forces in lead-in training and light attack roles. In , the Yak-130 fleet relies on these engines for enhanced and thrust-to-weight ratios, enabling subsonic combat maneuvers during training exercises. Interest from countries including has been noted for the Yak-130, supporting potential expansions in training and light combat roles. In the realm of rotary-wing , Ivchenko-Progress contributes indirectly to the Mi-8/17 series through collaborative developments like the VR-17MS main gearbox, optimized for integration with the TV3-117 engines powering these platforms. The Mi-8/17 family, exported to over 50 countries, has accumulated millions of flight hours in military transport and utility roles worldwide, underscoring the reliability of associated systems in diverse operational environments. Drone applications represent a growing focus for Ivchenko-Progress, with the AI-322 engine selected to power the (TAI) Anka III stealth (UCAV). This engine enables the Anka III to achieve speeds up to 425 knots and conduct internal weapons bay operations, as demonstrated in guided munition launch tests conducted in January 2025. The afterburning variant, AI-322F, provides up to 41.2 kN of thrust, enhancing the UCAV's supersonic potential and survivability features such as anti-icing systems for all-weather operations. Additionally, Ivchenko-Progress supplies variants like the AI-25TL series for other Turkish UAV projects, bolstering export successes in . In 2025, announced plans to begin ground tests in 2026 of a domestic engine to replace the AI-222 in its Low-Observable Wingman-Unmanned System (LOWUS) stealth drone, addressing concerns amid geopolitical tensions while validating the engine's integration with high-subsonic fighters like the KF-21. Post-2022, Ivchenko-Progress has sustained contributions to Ukraine's defense by continuing engine production and exports, including the AI-25TL for long-range cruise missiles like the FP-5 and supporting international partnerships that enhance Ukraine's military-industrial resilience.

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