SAMPE Technical Sessions : Extreme Composites

• 15.00-15.20: From Fan to Hot Section: GE’s Composite Innovation Journey by Dr. Gregory Gemeinhardt, Chief Consulting Engineer, Composite Materials, GE Aerospace, SAMPE North America

GE Aerospace has been a pioneer in the use of advanced composites to improve jet engine performance, durability, and efficiency. In fan systems, carbon fiber composite fan blades and cases—first proven on the GE90 and advanced on the GEnx and GE9X—deliver significant weight reduction while maintaining exceptional strength and impact resistance, contributing to lower fuel burn and quieter operation. Inside the hot section, ceramic matrix composites (CMCs) enable components such as shrouds, nozzles, and combustor/HP turbine parts to withstand much higher temperatures than metallic alloys at a fraction of the weight, allowing higher operating temperatures, improved thermal efficiency, and reduced cooling air requirements. Critically, each engine zone—fan, compressor, and turbine—presents unique mechanical, thermal, and environmental challenges that composites must address to ensure a viable, balanced design across the whole propulsion system. Combined, these composite technologies support better thrust-to-weight ratios, lower emissions, and improved reliability, helping airlines reduce operating costs and environmental footprint while advancing propulsion capability for today’s and next-generation engines.

• 15.20-15.40: Current Challenges on Ablative Composite Materials for Chemical Rocket Propulsion by Prof. Maurizio Natali, University of Perugia, Italy, SAMPE Europe

During the last decades, a plethora of Thermal Protection System (TPS) materials designed for chemical rocket propulsion - especially Solid Rocket Motors (SRMs) and, more recently, Hybrid Rocket Motors (HRMs) - have been developed. Among them it is worth mentioning Carbon Phenolic Composites (CPCs) and Carbon Carbon Composites (CCCs). Through the use of techniques such as Liquid Silicon Infiltration (LSI), CCCs can be converted into Carbon Silicon Carbide Composites (CSiCCs). These TPS materials are mainly used to manufacture rocket nozzle assembly components, jet vanes, etc, but they can also be employed to produce the heat shield of probes and space vehicles which are essential during re-entry- or hypersonic-flight. Depending on the application, each TPS material can offer a balanced compromise in terms of thermal insulation capability and erosion resistance. However, some challenges still remain in several areas of TPS materials such as on the possibility to: 1) push down their cost; 2) quickly produce n-D dry carbon preforms to maximize the erosion resistance; 3) introducing fully automated manufacturing techniques which minimizes the use of human manpower. In this survey, the state of the art of these TPS Materials will be first covered then showing some exotic applications and the most challenging R&D areas.

• 15.40-16.00: Extreme Composites for Aerospace Applications by Kaidi Huang, Engineer, AVIC Composite Corporation Ltd, SAMPE China

Extreme composites are high-performance material systems designed to maintain stable performance under harsh conditions such as high temperature, high pressure, and strong corrosion. This review focuses on the aerospace field, providing a systematic overview of key materials, including ceramic matrix composites, carbon/carbon composites, and new high-temperature-resistant polymer matrix composites. By summarizing recent research developments on extreme composites both domestically and internationally, the key aerospace applications are highlighted, such as aircraft thermal protection systems, rocket engine combustion chambers, and primary load-bearing structures of spacecraft. Finally, prospects for the future development of extreme composites are discussed in response to increasing demands for extreme material tolerance and multifunctional integration in future aerospace missions.