Lightweight jet engine mount optimization via finite element analysis and multiscale characterization

Abstract This work presents the computational design of a lightweight jet engine mount bracket based on multiscale experimental characterization of recycled AA2024 aluminum alloy. The alloy was processed through melting and casting, followed by solution heat treatment at 530 °C for 1 h and subsequent water quenching. Three heat treatment conditions were investigated: the solutionized condition without aging, and two T6-aged conditions with artificial aging at 180 °C for 2 and 24 h, respectively. Microstructural evolution was analyzed using scanning electron microscopy and energy-dispersive spectroscopy, supported by CALPHAD thermodynamic simulations. Mechanical behavior was evaluated via Vickers microhardness and compression testing. The T6 condition aged for 24 h at 180 °C exhibited the highest mechanical performance, with a 60% increase in strength compared to the solutionized condition. These results were used as input for finite element simulation and design optimization of a GE90-94B jet engine bracket under four critical loading conditions. The optimization achieved a 39% mass reduction while maintaining the minimum safety factor of 1.5. This integration of multiscale experiments and virtual design optimization demonstrates the viability of recycled AA2024 aluminum for producing lightweight aeronautical components.