| Citation: | ZHAO Shengyang, LIU Yuxin, LIU Cunliang, et al. Study on wear characteristics of brush seal bristle tips based on fluid-structure interaction modeling[J]. Journal of Aerospace Power, 2026, 41（8）：20250223 doi: 10.13224/j.cnki.jasp.20250223
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As aero-engines develop towards higher thrust-to-weight ratios and lower fuel consumption, the operating environment for brush seals has become increasingly harsh. Especially in high-pressure and high-speed environments, the tips of the brush filaments are prone to frictional wear against the rotor, which can lead to the failure of the entire sealing system. Based on a three-dimensional steady-state brush seal model and combined with the Archard adhesive wear theory, a fluid-solid coupling research method that can efficiently solve the frictional wear characteristics of brush filament tips under the condition of deforming brush filaments under multi-load effects was established. During actual operation, the rotor underwent thermal expansion/radial runout, causing severe interference with the brush filaments and thereby exacerbating the wear of the brush filament tips. Therefore, a detailed study was conducted on the wear characteristics of brush filaments under two scenarios: when the rotor’s radial position remained unchanged and when it returned to its original position. It revealed the influence of brush filament tip wear on the force, deformation, and leakage of the brush filaments, and compared the wear conditions under different pressure ratios and interference amounts. The research results showed that when the rotor’s radial position changed and returned to its original position, the contact force exerted by the rotor on the brush filaments in the upstream region was greater than that on the downstream brush filaments, resulting in faster wear. The wear amount increased most rapidly within the first 100 minutes and gradually stabilized after 300 minutes. When the rotor remained in the interference position, the wear rate of the brush filaments was 29.7% faster than when the rotor returned to its original position after wear. The sharp increase in leakage mainly occurred within 0—50 minutes from the start of wear. The reasons for the sharp increase in leakage were different under the two scenarios: in the case where the rotor returned to its original position, the leakage increased due to the enlargement of the radial gap; in the case where the rotor remained in the interference position, the increase in leakage depended on the arrangement state of the brush filaments.
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