Failure Mechanism and Engineering Validation of an Improved PEEK–CFRP Stator Shielding Sleeve for High-Speed Permanent Magnet Shielded Motors

High-speed permanent magnet synchronous motors (PMSMs) used in electric pump-fed liquid rocket engines require stator shielding sleeves to prevent corrosive propellants from causing harm under cyclic pressure. However, metallic sleeves suffer significant losses due to eddy currents. Conversely, pure carbon fiber reinforced polymer (CFRP) sleeves have failed when exposed to 98% H2O2. Micro-CT analysis of a failed pump sleeve reveals a four-stage failure mechanism. Manufacturing defects caused matrix cracking, which propagated under pressure and thermal cycling. This progression resulted in the formation of through-thickness leakage paths, which ultimately triggered catalytic decomposition and explosion. To address these issues, an improved dual-layer sleeve is proposed, featuring a 2.5 mm PEEK 450G liner and a 2.0 mm T700S/epoxy CFRP overwrap. Finite Element Analysis (FEA) indicates peak von-Mises stresses of 86.25 MPa and 112.16 MPa, yielding Tsai–Wu safety factors of 2.9 and 1.7. Furthermore, various tests, including immersion, fatigue, burst, hydraulic, and thermal evaluations, demonstrate a burst margin of 2.37× at 7.12 MPa, with only 0.19% increase in mass. This design effectively eliminates leakage pathways while preserving zero eddy-current loss and ensuring a low weight.