SAMULET Programme: High Efficiency Turbomachinery Project 1

A jet engine's hottest turbine blades will soon face higher temperatures and more corrosive exhaust, thanks to new coatings, cooling methods, and casting techniques being developed in this project. The problem is straightforward: aircraft engines burn fuel to produce thrust, and the hotter they run, the more efficient they become. But extreme heat degrades metal components, causing oxidation, fatigue, and corrosion that shorten engine life and increase maintenance costs. Current turbine materials and coatings are approaching their limits. This project targets that ceiling by improving the fundamental understanding of how oxidation and fatigue interact with coatings, then using that knowledge to design better alloys, protective layers, and cooling geometries. If successful, the technologies will reduce fuel burn and CO₂ emissions per flight—a direct environmental and economic benefit. They will also improve component life prediction, meaning airlines can schedule maintenance more precisely rather than replacing parts early as a safety margin. The work draws on Rolls-Royce’s University Technology Centres and includes high-speed rig testing of new aerodynamic designs, as well as new casting methods for single-crystal alloys that can withstand higher operating temperatures. The result is quieter, more efficient engines that stay in service longer.