Techno-Economic analysis of ceramic matrix composites integration in remaining useful Life Aircraft Engine Hot Section Components

Abstract Ceramic Matrix Composites (CMCs), specifically SiC/SiC composites, represent a significant innovation in aerospace material technology, offering superior performance over traditional nickel-based superalloys in high-temperature turbine blade applications. This study presents a novel techno-economic assessment, filling a critical gap in the literature by directly comparing the economic and technical viability of CMCs versus superalloys. Unlike previous studies, which primarily focus on technical performance or cost analysis independently, this work integrates both aspects, providing a holistic comparison across key economic metrics, including acquisition, machining, maintenance, and recycling costs. The results demonstrate that SiC/SiC blades offer a 15–20% higher Net Present Value (NPV) and a 17% greater Internal Rate of Return (IRR) over a 20-year lifecycle than superalloys. Despite higher initial costs, CMCs achieve an estimated 2 to 3 years reduction in payback period, mainly due to their superior thermal and creep resistance, leading to fewer maintenance interventions and longer operational lifetimes. Although machining costs for CMCs are higher, these are more than offset by the long-term savings achieved through improved fuel efficiency and lower maintenance costs. A comprehensive sensitivity analysis, incorporating fluctuations in discount rates and material costs, further validates the economic robustness of CMCs in various operational scenarios. This study is the first to compare CMCs and superalloys, offering new insights into the financial implications of material selection in aerospace manufacturing. The findings present critical engineering recommendations that empower aerospace manufacturers and decision-makers to optimise material selection for improved efficiency and cost-effectiveness in high-performance turbine applications.