As the aerospace industry continues to push the boundaries of innovation, one thing remains clear: fundamental sciences are at the heart of ground-breaking technological advancements. “We emphasize the importance of fundamental sciences in developing talent for the future,” Alok Nanda, CTO of GE Aerospace said in an exclusive interview on The Hindu’s Interface podcast, highlighting the critical role of foundational knowledge in shaping the future of flight.

This talent philosophy underpins GE Aerospace’s ongoing contributions to aerospace technology. From material science breakthroughs to AI-driven engine maintenance and open fan design, GE Aerospace has been innovating at scale, nurturing talent and integrating deep scientific principles into research.

Advancing material sciences

Aerospace engineers are constantly challenged to develop materials that can withstand extreme conditions—particularly the high temperatures inside jet engines, which exceed the melting points of most known metals. To address this, GE Aerospace has made significant advancements in ceramic matrix composites (CMCs). These composites combine ceramic fibres with a ceramic matrix, offering the high temperature resistance of ceramics along with improved toughness, which is crucial for engine durability.

“We’ve developed CMCs that allow us to achieve the temperature resistance needed for modern jet engines, while also ensuring the material’s toughness. This is a fundamental scientific breakthrough that has taken over two decades to perfect,” Mr. Nanda explained.

These materials are already being used in GE Aerospace’s LEAP engines and will feature even more prominently in future engines, including the GE9X, which powers Boeing’s 777X aircraft. By relying on these advanced materials, GE Aerospace is ensuring that engines are not only more efficient but also capable of withstanding the extreme conditions of flight for longer periods.

Designing for efficiency and sustainability

GE Aerospace is innovating on the open fan engine design that promises to reduce fuel consumption by up to 20%. The open fan design is based on the concept of using a larger, exposed fan to improve the efficiency of the engine, but it also presents unique challenges, particularly with regard to noise and safety.

“The benefits of an open fan are obvious—it increases efficiency and reduces fuel consumption,” Nanda said. “However, noise reduction and ensuring safety standards are met have been significant hurdles. Thanks to advances in computational power and understanding the underlying physics, we have made breakthroughs in these areas, bringing us closer to commercial viability.”

By combining high-performance computing with an in-depth understanding of materials and aerodynamics, GE Aerospace has made significant progress in solving these issues, with open fan engines now poised to play a key role in future aircraft designs.

AI in predictive maintenance and engine design

AI is revolutionizing both the design and maintenance of engines, helping companies like GE Aerospace optimize their products for efficiency and safety.

“Using AI, we can analyse real-time data from engine inspections and predict when maintenance should be performed. This reduces downtime, improves operational efficiency, and helps airlines get the most out of their fleets,” Nanda highlighted.

AI is also aiding in engine design, where computational tools allow engineers to explore the design space in far greater detail than before. With access to vast computing power, engineers can now simulate various configurations and optimize designs faster and more accurately, leading to more efficient and durable engines.

“The physics behind engine performance is complex, but AI helps us understand it more deeply. It enables us to push the boundaries of design, which is essential for developing engines that are not only more efficient but also more sustainable,” Nanda added.

Connecting fundamental sciences to emerging technologies

From material science to AI-driven optimization, the integration of deep scientific knowledge with cutting-edge technologies is setting the stage for the next generation of flight. For GE Aerospace, this focus on science is not just about developing new products; it’s about ensuring that the talent behind these innovations is equipped with the skills to solve the challenges of tomorrow.

“By developing a deep understanding of science and how to apply it, we can continue to push the envelope of innovation,” Nanda shared.

But there is no “silver bullet” that will solve all problems at once, Nanda cautioned. Instead, the industry must continue to mature technologies, iterating and refining them to meet the demands of the future.

(Listen to the full discussion with Alok Nanda on the Interface podcast or watch the YouTube video for more insights.)