Hot corrosion damage modeling in aeroengines based on performance and flight mission

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.