Thermomechanical Analysis of the GTM 400 MOD Turbojet Engine Nozzle During Kerosene and Hydrogen Co-Combustion

This study investigated the thermomechanical behaviour of the nozzle of a GTM 400MOD miniature turbojet engine during combustion of aviation kerosene and co-combustion of kerosene with hydrogen. Numerical analysis was based on experiments conducted on a dedicated test rig at engine speeds ranging from 31,630 rpm to 65,830 rpm, providing data on the temperature and dynamic pressure at the nozzle outlet. These data served as input to numerical analyses using the ANSYS Fluent, Steady-State Thermal, and Static Structural modules to evaluate exhaust gas flow, temperature distribution, and stress and strain states. The paper performed a basic analysis with additional simplifications, and an extended analysis that took into account, among other things, thermal radiation in the flow. The results of the basic analysis show that, at comparable thrust levels, co-firing and pure kerosene combustion yield similar nozzle temperature distributions, with maximum wall temperatures ranging from 978 K to 1090 K, which remain below the allowable limit of 1193 K (920 °C). Maximum stresses reached approximately 261 MPa, close to but not exceeding the yield strength of 316 stainless steel. Maximum nozzle deformation did not exceed 0.8 mm. Small dynamic pressure fluctuations were observed; For example, at 31,630 rpm, co-firing increased the maximum dynamic pressure from 1.56 × 104 Pa to 1.63 × 104 Pa, while at 47,110 rpm, it decreased from 4.05 × 104 Pa to 3.89 × 104 Pa. The extended analysis yielded similar values for the nozzle temperature and pressure distributions. Stress and strain increased by more than 76% and 78%, respectively, compared to the baseline analysis. The results confirm that hydrogen co-firing does not significantly alter the nozzle thermomechanical loads, suggesting that this emission-free fuel can be used without negatively impacting the nozzle’s structural integrity under the tested conditions. The methodology, combining targeted experimental measurements with coupled CFD and FEM simulations, provides a reliable framework for assessing material safety margins in alternative fuel applications in small turbojet engines.