Morphological and Compositional Evolution of Oxidative Coke Deposits Layers Generated by Aviation Kerosene

Thermal–oxidative coking of aviation fuel remains a critical limitation for fuel-cooled aero-engine systems operating under high heat loads. This study systematically investigates the oxidative coking behavior of RP-3 aviation kerosene, focusing on the coupled evolution of deposit morphology, composition, and operating conditions. Experiments were conducted in an electrically heated stainless-steel tube while independently varying dissolved oxygen concentration, fuel temperature, temperature gradient, operating pressure, and heating duration. Deposit layers were characterized by SEM and XPS, and residual fuel chemistry was analyzed using GC/MS. The results show that dissolved oxygen governs both the extent and mechanism of coking in the autoxidation regime (150–450 °C). Normal and elevated oxygen levels promote autoxidation of straight-chain alkanes, generating oxygen-containing intermediates that form flocculent, oxygen-rich deposits, whereas near-deoxygenated conditions suppress autoxidation but sustain sulfur-dominated, needle-like deposits. Temperature primarily controls deposition rate and morphology, with steep temperature gradients inducing localized coke formation, while pressure exerts only a minor indirect influence. Prolonged operation leads to deposit densification and non-linear accumulation behavior. These findings clarify the links between fuel chemistry, thermal conditions, and deposit architecture, providing a basis for morphology-aware coking models in fuel-cooled aero-engine systems.