This article is based on an official press release from GE Aerospace.

Out of Thin Air: GE Aerospace Deploys Next-Generation Dust Ingestion Testing Rig

For commercial airlines operating in arid, hot, and harsh environments, microscopic airborne particles present a relentless threat to engine durability. Over years of service, ingested dust gradually degrades internal components, forcing premature maintenance and grounding aircraft. To combat this, GE Aerospace has successfully developed and deployed a next-generation dust ingestion testing rig, fundamentally changing how the aviation industry evaluates engine resilience.

According to an official press release from GE Aerospace, this breakthrough was spearheaded by Senior Test Engineer Michael Mutchler, affectionately known within the company as “Dr. Dust.” By shifting the fundamental engineering approach to how dust is handled during testing, Mutchler and his team have created a system capable of enduring grueling, months-long evaluation cycles without breaking down.

The new testing apparatus is already proving its worth. GE Aerospace reports that the rig is currently being utilized to test components for the CFM RISE program, a next-generation engine demonstrator, years ahead of scheduled flight tests. This marks the earliest the manufacturers has ever conducted dust ingestion testing on a technology demonstration program, signaling a proactive shift in how engine durability is prioritized.

The Engineering Breakthrough: Treating Dust as an Aerosol

Overcoming Mechanical Failure

Unlike standard icing tests, which can reveal engine vulnerabilities within a matter of hours, dust ingestion testing is a marathon. According to GE Aerospace, these tests can take up to six months to complete. The primary challenge historically has not just been engine survival, but the survival of the testing equipment itself. If a testing rig fails midway through a cycle, months of valuable data can be lost.

The catalyst for the new rig occurred in the summer of 2021 during a testing mission at GE Aerospace’s Global Research Center in Niskayuna, New York. Mutchler and his team observed that their equipment was failing under the mechanical stress of continuously delivering dust into the engines.

“We noticed that the old testing equipment was mechanically excited. In fact, it was kind of tearing itself apart,” Mutchler stated in the company release.

The “Aerosol” Solution and “Pixie Dust”

The breakthrough came when Mutchler identified a critical mental barrier in the engineering process: the team had been treating the ingested dust strictly as a solid. To relieve the mechanical stress on the equipment, he proposed treating the dust as an aerosol.

“We were still thinking about dust as just a solid substance. But it’s actually an aerosol, and can act like a solid and a gas at the same time,” Mutchler explained.

Following this realization, Mutchler collaborated with Daniel Ellestad, specialists in Bengaluru, India, and a team of expert geologists and chemists to redesign the “metering rig.” The company notes that this motor-driven apparatus uses high-pressure air to propel a consistent, controlled amount of proprietary dust into the engine’s flow path. This proprietary mix of sand and particles, dubbed “pixie dust” by the engineers, was specifically developed to perfectly mimic real-world atmospheric conditions found in regions like Dubai.

Stress-Testing the Future of Flight

The CFM RISE Program

The newly developed testing rigs have been installed at GE Aerospace’s Evendale, Ohio campus and its Peebles Test Operation. With simple nozzle modifications, the company states the rig can test all of its engine lines, including the highly anticipated CFM RISE program. Unveiled in 2021 by CFM International (a 50-50 joint venture between GE Aerospace and Safran Aircraft Engines), the RISE program features an “Open Fan” architecture that targets a 20 percent improvement in fuel efficiency compared to current commercial engines.

In late 2025, CFM began utilizing Mutchler’s rig to conduct dust ingestion testing on the RISE program’s next-generation high-pressure turbine (HPT) airfoils and compact engine core. The rig injects dust over thousands of cycles, simulating takeoff, climb, cruise, and landing phases.

“With the RISE technology demonstration program, we’re pursuing durability and efficiency improvements with equal focus,” said Arjan Hegeman, Vice President for the Future of Flight at GE Aerospace.

Peebles Test Operation

The grueling dust ingestion tests are primarily conducted at the Peebles Test Operation, a sprawling 7,000-acre facility in southern Ohio. Originally established in 1954 as a rocket engine test site, GE Aerospace notes that Peebles now serves as the primary testing ground for commercial engines, including the GE90, GEnx, GE9X, and CFM LEAP.

AirPro News analysis

At AirPro News, we view this development as a critical step forward for airline operational economics. Dust ingestion is a primary driver of “time-on-wing” degradation for carriers operating in the Middle East, North Africa, and parts of Asia. When engines ingest microscopic sand and dust, the resulting wear on turbine blades and internal cores forces airlines to remove and overhaul engines far sooner than they would in temperate climates. By successfully modeling dust as an aerosol and testing next-generation architectures like the CFM RISE early in the development cycle, GE Aerospace is directly addressing one of the most costly maintenance pain points for global operators. If the RISE program can achieve its stated 20 percent fuel efficiency gains without sacrificing durability in harsh environments, it will represent a massive competitive advantage in the next decade of commercial aviation.

Frequently Asked Questions (FAQ)

What is dust ingestion testing?
Dust ingestion testing is a process where jet engines are subjected to controlled amounts of airborne particles (like sand and dust) over long periods to simulate the wear and tear they experience in harsh, arid environments.

Why did GE Aerospace need a new testing rig?
According to the company, previous testing equipment was physically breaking down under the mechanical stress of delivering solid dust over testing cycles that can last up to six months.

What is the CFM RISE program?
The CFM RISE program is a technology demonstrator developed by CFM International (a joint venture between GE Aerospace and Safran). It aims to develop an “Open Fan” engine architecture that delivers a 20 percent improvement in fuel efficiency.

Sources

• GE Aerospace