Corrosion Risk Estimation and Cause Analysis on Turbofan Engine

Lacaille, Jérôme; Langhendries, Raphaël

doi:10.36001/phmconf.2022.v14i1.3254

Cited by 2 publications

(1 citation statement)

References 11 publications

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“…Apart from the hot corrosion experiments that modeled the phenomenon from the perspective of material science using some typical boundary conditions, there are very few studies in literature that connected hot corrosion damage with operational parameters in the highly varying aero-engine conditions. Lacaille et al [43] developed a probabilistic framework using neural networks to predict the probability of cumulative hot corrosion wear on the turbine stators of a turbofan engine. They used real flight information (duration, environmental exposure, number of flights) for each Engine Serial Number along with accumulative wear based on inspection findings.…”

Section: E State Of the Art In Hot Corrosion Life Prediction Based On...mentioning

confidence: 99%

Hot Corrosion Damage Modelling in Aero Engines based on Performance and Flight Mission Analysis

Pontika

Laskaridis

Nikolaidis

et al. 2023

AIAA SCITECH 2023 Forum

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Lifing models for aircraft engines are mainly focused on creep, fatigue and oxidation, while hot corrosion remains one of the least explored areas. Hot corrosion is a form of chemical damage that causes surface degradation, sound material loss and reduced component life. A lifing analysis for aircraft engines without considering hot corrosion can lead to unexpected and unexplained hot corrosion findings by aircraft engine operators and Maintenance, Repair and Overhaul (MRO) providers during inspections. Although hot corrosion does not cause failure on its own, the interaction with other damage mechanisms can reduce component life significantly. Consequently, there is a necessity for including hot corrosion in the damage prediction process of aircraft engines. This paper presents a new methodology to estimate hot corrosion damage based on aero-engine performance and flight mission analysis while taking into account environmental exposure, fuel quality and material factors. The analysis in the present paper focuses on the hot corrosion progress over the course of the flight mission, while varying the major contamination factors and thrust derate, and the hot corrosion rate over flight time is then used to calculate the damage at the end of the mission. The participating mechanisms, from salt and sulfur impurity ingestion to deposition rate and hot corrosion attack, are analytically presented to explain the progress of the phenomenon in aero-engine components. In the investigated type of engine, the first stage of the low-pressure turbine is found to be the most affected. It is concluded that hot corrosion is favored by a combination of high pressure, high sulfur oxide concentration, and high salt deposition rate within an intermediate temperature range while the gas conditions near the component surface remain below the sodium sulfate saturation point, and these conditions are linked with aero-engine operation. The presented hot corrosion framework captures the effect of mission requirements, component operating conditions, environmental exposure, fuel quality and material on the hot corrosion damage of hot section components. It can be used to inform aero-engine maintenance planning, lifecycle analysis and MRO contract-costing, and can benefit digital twins for predictive maintenance.

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Section: E State Of the Art In Hot Corrosion Life Prediction Based On...mentioning

confidence: 99%

Hot Corrosion Damage Modelling in Aero Engines based on Performance and Flight Mission Analysis

Pontika

Laskaridis

Nikolaidis

et al. 2023

AIAA SCITECH 2023 Forum

View full text Add to dashboard Cite

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Hot Corrosion Damage Modeling in Aeroengines Based on Performance and Flight Mission

Pontika,

Laskaridis,

Nikolaidis

et al. 2024

Journal of Thermophysics and Heat Transfer

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Hot corrosion is a form of chemical damage that causes surface degradation, sound material loss, and reduced component life. A lifing analysis in aeroengines without considering hot corrosion can lead to unexpected damage findings and increased scrap rates due to blade thickness loss beyond repair. This paper presents a novel methodology to predict hot corrosion damage based on aeroengine performance and flight mission analysis while taking into account environmental exposure, fuel quality, and material factors. The participating mechanisms, from salt and sulfur ingestion to deposition and hot corrosion attack, are discussed to explain the phenomenon in aeroengine components. In the investigated engine type, the first stage of the low-pressure turbine is the most affected. The application of the new methodology provides insights into the damage progression during the flight, the most affected components and the importance of capturing variations in the fuel quality, environmental exposure at the flight region, and the thrust derate policy. For a representative 1500 n mile mission, the variations in environmental exposure, fuel quality, and derate policy within typical limits can result in up to +350% damage. The outputs of the new framework can inform the decision making for maintenance, repair, and overhaul contract costing and scheduling.

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Corrosion Risk Estimation and Cause Analysis on Turbofan Engine

Cited by 2 publications

References 11 publications

Hot Corrosion Damage Modelling in Aero Engines based on Performance and Flight Mission Analysis

Hot Corrosion Damage Modelling in Aero Engines based on Performance and Flight Mission Analysis

Hot Corrosion Damage Modeling in Aeroengines Based on Performance and Flight Mission

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