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Integrated CFD–FEA thermal analysis of an aft-fan module for a mini turbojet engine
 
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1
Mechanical Engineering Department, Turkish Naval Academy, National Defense University, Tuzla 34942, İstanbul, Türkiye
 
2
Mechanical Engineering Department, Atatürk Strategic Studies and Graduate Institute, National Defense University, 34334 Yeni Levent, Beşiktaş, İstanbul, Türkiye
 
3
Department of Materials Engineering, Faculty of Mechanical Engineering, Lublin University of Technology, ul. Nadbystrzycka 36, 20-618 Lublin, Poland
 
4
Mechanical Engineering Department, Istanbul Gedik University, 34876 Kartal, İstanbul, Türkiye
 
 
Corresponding author
Doğuş Özkan   

Mechanical Engineering Department, Turkish Naval Academy, National Defense University, Tuzla, 34942, İstanbul, Türkiye
 
 
Adv. Sci. Technol. Res. J. 2026; 20(11):126-143
 
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ABSTRACT
This study presents an integrated CFD–FEA thermal analysis of an aft-fan module designed for a mini turbojet engine, employing a hierarchical approach that combines one-dimensional heat-transfer formulations, two-dimensional disc conduction–convection models, and three-dimensional CFD-assisted solid thermal simulations. CFD-derived convection coefficients and secondary air system (SAS) cooling conditions were mapped onto the solid domain to obtain a realistic temperature field under combined hot- and cold-flow conditions. The results indicate a maximum metal temperature of ≈979 K on the turbine rotor blades, while the fan-side components remain near ≈294 K, establishing a pronounced through-disc thermal gradient driven by the 1045 K turbine inlet gas. The analytical and three-dimensional numerical models produced closely matching temperature distributions along the rotor and casing, demonstrating consistency between the modelling approaches. Materials were selected based on the predicted thermal loads: Inconel 738 for the hot-side components, Ti–6Al–4V for the cold-side aerodynamic surfaces, Inconel 718 for the highly loaded covers, and AISI 410 for the shaft. The presented workflow provides a systematic numerical framework for the thermal assessment of aft-fan modules and offers new insights into heat-load management and temperature-driven design constraints in next-generation mini and micro turbojet propulsion systems.
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