Simulation and Evaluation of Advanced Long life Seals (SEALS)

A new generation of gas turbine seals could cut fuel burn and carbon emissions by allowing engine parts to adapt to movement rather than relying on fixed gaps. Conventional labyrinth seals rely on tight clearances and abradable materials that wear down over time, limiting how well they contain high-pressure air. This leakage reduces engine efficiency. The SEALS project, led by Rolls-Royce, developed numerical and experimental models for advanced seals that actively accommodate radial movement, maintaining much smaller clearances during operation. The core problem is that existing seals cannot respond to changing conditions inside a running engine, wasting energy. If these advanced seals are adopted, gas turbine engines—used in aircraft propulsion and power generation—would burn less fuel and emit less carbon dioxide. The impact is twofold: lower environmental harm from aviation and energy production, and stronger export revenue for UK industry through more competitive products. The project did not test seals in operational engines; it built and validated the simulation tools needed to design them. Success means manufacturers can move from concept to prototype with confidence, quietly improving the efficiency of systems that move people and power the grid.