Numerical and Experimental Investigation of Damage and Failure Analysis of Aero-Engine Electronic Controllers Under Thermal Shock

The Engine Electronic Controller (EEC), as the core component of an aircraft engine control system, is vulnerable to rapid failure when exposed to thermal shock during engine fire incidents, potentially leading to catastrophic aviation accidents. To address this issue, this study conducts both numerical simulations and experimental investigations to evaluate the thermal performance of the EEC under thermal shock conditions, exploring the weaknesses of the EEC chassis under high-temperature thermal shock and the damage to important internal electronic components. A three-dimensional finite element model of the EEC was established to simulate its behavior under a thermal shock of 1100 °C. Simulation results reveal that the aluminum alloy chassis wall cannot withstand the extreme thermal load, resulting in failure of the internal electronic components within the first 5 min of exposure, thereby rendering the EEC inoperative. In contrast, when the chassis wall is made of stainless steel, all components and internal electronics remain functional throughout the initial 5 min thermal shock period. Experimental results show that the temperature evolution and component failure patterns under both scenarios align well with the simulation outcomes, thus validating the model’s accuracy.