Micro Robots Capable of Repairing Aircraft Engines

Aviation Travel

Mechanical EngineerMicro Robots Will Repair Jet Engines from the Inside

If you are reading this article while on a plane and you are a bit of a nervous person, please do not panic because of the following text: the temperature inside the jet engine that takes you flying at high altitude can exceed the melting point of the materials used to manufacture the engine. However, the engine does not melt into a pile of scrap metal; this is indeed a significant achievement of modern engineering technology. This includes sturdy alloys and advanced production processes, such as 3D printing. 3D printing can produce components with fine channels through which cooling air can circulate. Components exposed to the most extreme temperatures—possibly exceeding 1300°C—are also wrapped in a layer of special heat-resistant ceramics as an additional protective measure.

New jet engines need to operate at elevated temperatures because this allows for more complete combustion, thereby reducing fuel consumption and emissions. However, engines that operate at high temperatures require maintenance. Today, the world’s three major aircraft engine manufacturers—General Electric, Rolls-Royce, and Pratt & Whitney—typically include maintenance as part of their sales, and many jet engines are rented under “hourly maintenance contracts.” This indicates that regular inspections and maintenance benefit both airlines and manufacturers. The challenge is how to inspect engines without disassembly. This requires the aircraft carrying the engine to stop service. Additionally, under hourly maintenance contracts, when an aircraft enters the maintenance workshop, it is not just the airline that loses money; the engine manufacturers do as well. Therefore, people are searching for faster and more effective ways to keep engines in optimal condition.

At General Electric’s global research center in Niskayuna, New York, chief scientist Don Lipkin and his colleagues Todd Danko and Kori Macdonald believe they have found a solution. They are developing micro robots that can probe inside the engine to inspect equipment and perform necessary repairs. Ultimately, these robots may be able to work while the aircraft is at the gate during flight intervals.