Failure analysis of the premature fan blade-off in aeroengine containment test

• Published in: Engineering failure analysis Vol. 180; p. 109888
• Main Authors: Yang, Wenjun, Wang, Yinhao, Li, Jichen, Hao, Junfeng, Gao, Jiran
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.10.2025
• Subjects: Aeroelastic coupling; Aeroengine fan; Failure analysis; Mises strength criterion; Premature blade-off; Mises strength criterion; Aeroengine fan; Premature blade-off; Aeroelastic coupling; Failure analysis
• ISSN: 1350-6307
• DOI: 10.1016/j.engfailanal.2025.109888

•The fan blade containment test is conducted in non-vacuum conditions, reflecting the real service environment of aeroengines.•Considering the rotor–stator interaction, a fluid–structure interaction numerical model of the pre-notched fan blade is established.•A lower-order resonance induced by the prefabricated notch is not the primary reason for blade-off.•Aerodynamic bending moments in non-vacuum environments caused multiaxial stresses on the pre-notched blade, leading to premature blade-off. The fracture of fan blades caused by the foreign object damage is a serious threat to the aeroengine service safety. To investigate the impact effect after blade-off, an aeroengine containment test is conducted under non-vacuum conditions. However, the pre-notched fan blade detaches prematurely at a rotational speed below the design threshold. To explain this anomaly, this study combines the numerical and theoretical approaches to analyze the failure causes. Firstly, a structural model of the pre-notched fan blade is established, and modal analysis is conducted to assess the potential influence of resonance on failure. Subsequently, considering the rotor–stator interference caused by support plates, a model of the unsteady flow field is established. Finally, a fluid–structure interaction (FSI) method is employed to explore the influence of coupled aerodynamic and centrifugal loads on stress distribution. The results indicate that resonance effects are not the primary cause of blade failure. In the non-vacuum environment, the introduction of aerodynamic load subjects the blade to complex multiaxial stress states. Compared to the condition with only centrifugal loading, the Mises stress at the notch increases by 15.2%, exceeding the ultimate tensile strength of the TC4 alloy and finally leading to the premature blade-off.