he EJ200 engine was designed and de-veloped by the European Eurojet Consor-tium, founded in 1986 through the union

of four European companies working in part-nership in advanced technological aeroenginedevelopment, Rolls-Royce (UK) 33%, MTU(Germany) 33%, Avio (Italy) 21% and ITP(Spain) 13%. Started in 2001, production wasslated for 1,400 EJ200 engines, which powerthe 620 Typhoon fighter aircraft. Besides its in-stallation on the Typhoon, which will also besold to countries other than the Eurojet partnernations, the EJ200 will be produced for othersingle- or twin-engine aircraft currently in-ser-vice or under development.The Austrian Air Force elected to adopt the Ty-phoon as its new fighter; the Consortium deliv-ered all the 32 engines. Eurojet also supportsthe Austrian fleet ensuring the repair and over-haul of the engines.The Royal Saudi Air Force signed a contract for154 engines (of which 13 delivered up tonow) and, more recently, an agreement for thefirst support phase.Eurojet delivered more than 650 engines toCustomers.

EJ200: an enginefor extreme performancerequirementsThanks to its two EJ200 engines, which pro-vide a thrust of nearly 20,000 lb, the Typhooncan take off from extremely short runways.Compared with earlier military engines, theEJ200 enables a significant cost reduction of theweapons system life cycle, also thanks to the Inte-grated Logistics Support based on advanced soft-ware applications of information management.

TThe EurojetConsortium

EJ200Eurofighter - Typhoon

Military aviation

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Avio’s high technological know-how is interna-tionally acknowledged, and embraces the entirelife cycle of aeroengines, from design and de-velopment to assembly and technical and logisticssupport. As a partner in the EJ200 programme,Avio expanded its capabilities across various sys-tem disciplines, among which the developmentof a significant part of the engine monitoring andcontrol software, and the technical design defini-tion oriented towards reducing life-cycle costsand increased aircraft availability.This led to significant advances in technologiesthat confirm Avio’s commitment to provide itscustomers, especially domestic customers, withimproved and efficient services. Avio producedthe first EJ200 production engine in 2001 forthe Italian Air Force (IAF). Up to mid-December2007, 71 engines had been assembled anddelivered to the IAF, completing Tranche 1,and launching Tranche 2. At the end of 2008,Avio delivered the 100th engine. At the endof 2009, the number of Tranche 1 and Tranche2 engines delivered to the IAF was 120.

Aviofor the EJ200

Accessory Gearbox (AGB)The main body, which is made from a single cast-ing in magnesium, is connected to the accessoriesby adapters, which are also made from light alloy.The gearbox drives the engine accessories (com-bined oil pump, main fuel pump, tank with rotatingbasket, afterburner pump, air/oil separator andhydraulic pump) through six shafts, while the sev-enth supplies mechanical power to the gearbox.To reduce the complexity of the engine pipingsystem, the gearbox is equipped with oil andfuel lines created in the casting.

Low-Pressure Turbine (LPT)The entire system, which is divided into statorand rotor stages (including the low-pressureshaft), is a product of Avio engineering.To meet the tough requirements in terms of per-formance, weight and reliability, the turbinewas designed with the most up-to-date tech-nologies in materials (last-generation cooledsingle crystal rotor blades) and mechanicaland aerodynamic design. In addition to thestabilisation of high-pressure flow by the statorvane stage, the stator constitutes the rear en-gine support that holds the two rear bearings ofthe high- and low-rear shafts.

Avio-developedcomponents

Gearbox

Low Pressure Turbine Afterburner

Stator Rotor

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AfterburnerAvio is responsible for the entire afterburner sys-tem downstream from the fuel control valve andlight alloy lines, fuel spray control, injectors, flamestabiliser, noise suppresser and heat shields. Thegeometry of the afterburner was conceived sothat it reduces combustion instability, while resist-ing the extreme operating temperatures, andcools the flaps of the engine exhaust nozzle.The main function of the afterburner is to mix thecold bypass and main turbine streams. Thecontrol system ensures balanced throttle settingand thrust from the afterburner. At equal turboengine functioning, the afterburner increasesengine thrust up to 50% in order to improve air-craft take-off and combat performance.

Other systems• lubrication system with accessories such as oil

pump, tank, sensors and air/oil separator• engine oil Debris Monitoring System(DMS)•air system that cools engine components• stabilisation of internal loads and pressurisa-

tion of supports• hydraulic actuation system of variable geome-

tries: ‘inlet guide vanes’ of the HP compressorand the exhaust nozzle

• ignition system consisting of a high-power ig-nition box with dual independent channels topilot the low-voltage spark plugs

Aviofor the Typhoon

The Aircraft MountedAccessories Drive (AMAD)Avio’s involvement in the Typhoon does not stop atthe EJ200. The company is a leader in the DFZIConsortium, which was selected for developing theAMAD. Installed on the drive are the principal elec-trical and hydraulic accessories that generate thepower for flight function and command systems. Thepartners in the DFZI Consortium are Avio (Italy)40%, Liebherr (Germany) 30% and Moog (UK)30%. The Typhoon is equipped with two tandemgearboxes, each of which is connected to the gear-box on the engine that drives it.The accessories installed on the AMAD are:• compressed air actuation system (ATS/M)•Constant Frequency Generator (CFG)•Hydraulic Pump (HP)•Direct Current Generator (DCG)The main body of the box is made from a singlecasting in magnesium, and the accessories are con-nected through special adapters in light alloy.The AMAD functions in two ways:1 starting the main engine (EJ200) on the

ground and in-flight, and driving all the otheraccessories installed

2 the transmission of mechanical power from theengine to the connected electrical and hy-draulic accessories

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Auxiliary Power Unit (APU)Avio is a participating partner with Honeywell(Germany), CESA (Spain) and Honeywell (UK) inthe Consortium responsible for the design and de-velopment of the APU on the Typhoon. Within theConsortium, Avio, with a working share of 20%,is responsible for the development of the combus-tion chambers, external compressor and turbinecasings, as well as the assembly and testing of theunits that are installed on the aircraft produced forthe Air Forces of Italy, Spain and the UK (50%).

Propulsion in the sky, space and sea

Via I Maggio, 99 - 10040 Rivalta di Torino - Torino (Italy) - Tel. +39 011 0082111

www.aviogroup.com

To ensure the maximum efficiency and opera-tional availability of the weapons system forthe entire product life of the EJ200 (30 years);this is the main objective that Avio’s IntegratedLogistics Support has set itself since the initialphases of the project, and has contributed toguaranteeing the highest availability of the en-gine system.In collaboration with its partners, Avio has devel-oped technical manuals and training programmes,taking advantage of the most recent advances incomputer-aided learning technologies:• Interactive Electronic Technical Publications

(IETP): conforming to international specifica-tions, these manuals can also be placed onthe Internet or intranet

•Computer Based Training (CBT): training forengine technicians through specifically de-signed instruction content in various formats

of films, photographs, 3D animation, spokentexts and exercises that trainees must com-plete in order to go on to the next highercourse levels

Avio’s training centre in Brindisi (Italy) has atheoretical area covered by CBT, and a prac-tical area where On-the-Job-Training (OJT) iscarried out. The trainee can apply his theoreti-cal knowledge directly on the engine.Avio guarantees technical and maintenancesupport for the EJ200 at the customer’s operat-ing base. It also provides comprehensive MROservices for the entire engine and its compo-nents at Avio’s Centre of Excellence in Brindisi,which handles the service and maintenance ofmilitary aircraft engines.Furthermore, the Brindisi Centre of Excellenceis where the repair and overhaul of LH and RHAMAD gearboxes and auxiliary power units iscarried out.

Customer support

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