Rolls-Royce is trialling new technology at its Derby facilities in an effort to prevent sand and dust from damaging its jet engines.
The problem has long affected airlines flying in the Middle East — one of the company’s most crucial markets. During take-off, sand and fine dust can be drawn into the hottest parts of an engine, accelerating corrosion and raising internal temperatures when coolant holes become blocked.
While the issue does not compromise flight safety, it does reduce engine efficiency and increases how often maintenance is required, as protective coatings deteriorate more quickly.
“The dust can reach the hottest sections of the engine and cause those components to wear out far faster than they would if they weren’t exposed to sand,” says Pat Hilton, Rolls-Royce’s head of test facilities.
As part of its testing programme, Rolls-Royce has modified the metal alloys used in key components to improve heat and corrosion resistance. It has also relocated certain coolant holes to reduce the likelihood of blockages.
These developments fall under a broader £1bn durability initiative covering multiple engines, including the Trent XWB-97 — the company’s most powerful and hottest-running model.
Testing is being carried out in three stages at Testbed 80, Rolls-Royce’s state-of-the-art facility in Sinfin. Engines evaluated in the first two phases have since returned to service and are now able to operate 60% longer between overhauls, the company reports.
To support the work, the University of Manchester created a synthetic dust that replicates the extremely fine, talcum-powder-like particles common in Middle Eastern environments.
Hilton says the ultimate goal is to extend engine life significantly.
“What we’re aiming for with the improved fleet is to double the flying time before major maintenance is needed. It’s fantastic to know that the work we’re doing today will benefit engines flying for many years.”
Currently, a Trent engine can fly the equivalent of 500 trips around the world before key components must be replaced. Rolls-Royce expects this to double once final testing concludes in 2028.
Last year, Emirates Airline president Sir Tim Clark raised concerns about the durability of the Trent XWB-97, which powers the Airbus A350 — a mainstay of long-haul fleets used by carriers such as Emirates and Etihad.
Rolls-Royce says its ongoing programme is directly addressing these durability issues across the entire fleet.
