Scientists Use Synthetic Dust to Save Rolls-Royce Jet Engines

Jet engine builder Rolls-Royce has found a way to extend the lifespan of its jet engines, thanks to a new invention. Scientists at the University of Manchester created an artificial dust they have used to recreate desert conditions and build engines to withstand them.

According to a release on 16 December, the university’s Dust & Underground Science & Technology (DUST) group developed a synthetic test dust that accurately replicates the fine, talcum-powder-like particles commonly found in desert regions, responsible for accelerated wear on some aeroengine components.

The dust was used to simulate conditions in desert regions where jet engines easily harbor dust in order to build engines with higher resilience and ability to survive in such regions. The dust has become an important component of the company’s engine testing in Derby.

Solving the Problem of Sand in Rolls Royce

Rolls-Royce jet engines are used in different parts of the world including the Middle East where dust and sand is a major problem. Over the years, it has been observed that such sand is responsible for the fast wearing of jet engines used in those regions. In a bid to build more resistant ones, the scientists invented the artificial dust to simulate those deserts right in the lab.

The release says: 

“Sand ingested during take-off and climb can penetrate the hottest parts of an engine, corrode components, and block coolant holes. While not a safety issue, the damage reduces efficiency, increases the maintenance burden, and shortens component life.”

Using the artificial sand, Rolls-Royce has managed to replicate harsh Middle Eastern conditions inside its Testbed 80 facility in Sinfin. Engineers then tested new coatings with better resistance against heat and corrosion, and redesigned coolant holes so they are less prone to blockage.

According to Pat Hilton, Rolls-Royce’s Test Facilities Manager, engine changes have been tested with the synthetic raw material and modified engines have returned to service, showing a 60% increase in time between overhauls, demonstrating more resilience against dust-induced engine damage.

Rolls-Royce’s Reputation in Jet Engine Maintenance

Rolls-Royce has a reputation in the maintenance of jet engines as seen by its role in research and servicing. Last month, the company in the Middle East entered a partnership with Emirates to maintain its Trent 900 A380 engines. 

The research involving synthetic dust will help the company in making it better at maintaining Emirates engines especially against dust. Apparently, the discovery has added significantly to Rolls-Royce’s engine maintenance technology. Meanwhile, China is testing 3D-printed turbojet engines as a lightweight option to existing jet engines.

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