SEARCH · Engineering Papers
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Thermal management is a challenge for electric aircraft propulsion. This is because Current electrified aircraft concepts produce large amounts of low-grade waste heat and require large, heavy thermal management systems that cause drag. Currently, NASA is considering passive approaches for the X-57 and HEATheR projects to reduce these penalties.
Thermal management is a challenge for electric aircraft propulsion. This is because Current electrified aircraft concepts produce large amounts of low-grade waste heat and require large, heavy thermal management systems that cause drag. The High-efficiency Electric Aircraft Thermal Research project explored two ideas to solve this problem: building a low loss power system and using the aircraft skin to cool components through the outer mold line.
Electrified aircraft propulsion seeks to address ambitious goals in the commercial airline industry, including significant decreases in fuel burn, emissions, noise, and takeoff field length. In order to move these electrified propulsion concepts forward, analysis tools are needed that can model propulsion systems containing both gas turbine and power system components. This work presents the definition of an electric port, a set of electrical power systems tools, and simulation examples for the Numerical Propulsion System Simulation (NPSS) software. NPSS is the industry standard modeling and simulation package for aircraft propulsion systems, and the ability to design, size, integrate, and analyze electric power systems will enable industry efforts towards the development of electrified aircraft propulsion.
The dedicated air cargo and freight market has the potential to be a critical early pathway for emerging technologies in low to zero emission propulsion. This study analyzes the cargo aviation market to understand current market trends and future market viability of a mid-sized all-electric or hybrid-electric concept aircraft. While cargo aviation’s overall emissions footprint is small relative to commercial passenger aviation, it remains an important and challenging transportation sector to decarbonize. Past research has focused on small, less than 19-seat electrified aircraft propulsion concepts that could serve both passenger and air cargo markets. This study extends the electrified market space into larger aircraft classes, considering if a purpose-built large hybrid electric turboprop freighter can compete in the market currently served primarily by conversion narrowbody freighters. Specifically, this paper focuses on the mid-sized cargo market with payload ranges of 40,000-50,000lbs, and an all-electric range potential up to 750 miles. The concept aircraft is based on a 4-engine turboprop configuration, with wing mounted battery packs and an aft cargo door to allow for standardized palletization. The market analysis indicates broad market coverage with 73% of the existing mid-sized cargo network within the range of 750 miles. A breakeven analysis of operating and capital costs shows potential for market competition; however, this would require additional energy and acquisition cost savings from the concept aircraft. Evidence from the breakeven analysis also points to higher rates of aircraft utilization being a critical path to lowering costs and increasing cost effectiveness.
This paper will detail the design, sizing, and mission analysis for the thermal management system (TMS) for the Subsonic Single Aft eNgine (SUSAN) aircraft. Previous work has defined key performance parameters (KPPs) for the electrical power system on SUSAN. These KPPs, efficiency and specific power, were assigned values for each power system component at minimum, nominal, and maximum levels of technology development. The values were based on NASA’s research in Electrified Aircraft Propulsion (EAP) technology. A similar approach was taken in this work, defining and assigning values for KPPs for each component of the TMS. These KPPs are used as inputs to the TMS analysis and sizing and establish targets for future technology development. The minimum level is based on the current state of the art, using available data on commercial off-the-shelf products from suppliers, datasheets, or testing. The nominal level is based on recent published research and on-going NASA-funded work. The maximum level represents a projection of technology performance into the future.
The High Efficiency Megawatt Motor (HEMM) is being designed to meet the needs of Electrified Aircraft Propulsion (EAP). The key objective of this work is to establish a motor technology which simultaneously attains high specific power (>16kW/kg ratio to electromagnetic weight) and high efficiency (>98%) by judicious application of high temperature superconducting wire and integrated thermal management. Another important feature is to achieve the performance goals with an eye to aircraft integration constraints. An electromagnetic analysis was performed which shows that the proposed HEMM design meets the performance objectives if key current capability and mechanical constraints are achieved. Sensitivity of motor power and performance to those parameters is illustrated. The HEMM technology could be applied to a range of aircraft types that require megawatt level electrical power.
NASA is supporting the development of Electrified Aircraft Propulsion (EAP) technology due to its potential to reduce aircraft fuel burn, emissions, and noise as well as improving safety and performance. One focus of this research is the electrification of conventional turbomachinery propulsion systems, which offers ways to improve the performance and operability of turbine-engine powered aircraft through the addition of electro-mechanical systems. These hybrid-electric turbine engines provide additional actuation and energy management control opportunities for improving stability and transient response behavior. This paper summarizes the results of a Hardware-in-the-Loop (HIL) test performed at the NASA Electric Aircraft Testbed (NEAT) during the summer of 2022. The test demonstrates the feasibility and performance of an advanced energy management control strategy by integrating a simulated turbofan engine with scaled electro-mechanical hardware. A full-scale real-time reference model of a geared turbofan was run alongside a scaled electro-mechanical system representing the electrified turbofan components operating at a megawatt-scale power level. The model was interfaced with the hardware through a novel closed-loop control and scaling algorithm that emulated the dynamic speed and torque response of the turbofan shafts. The control strategy was implemented on the electrical machines connected to the emulated turbomachinery shafts. The results from the testbed are compared against simulations that predict the testbed and geared turbofan model operation. The energy management control strategy successfully changed the operating point of the engine model and improved its stability during throttle transients. These results also demonstrate the success of the novel closed loop control and scaling approach for emulating turbomachinery and elevate the Technology Readiness Level (TRL) of the energy management control strategy.
NASA is supporting the development of Electrified Aircraft Propulsion (EAP) technology due to its potential to reduce aircraft fuel burn, emissions, and noise as well as improving safety and performance. One focus of this research is the electrification of conventional turbomachinery propulsion systems, which offers ways to improve the performance and operability of turbine-engine powered aircraft through the addition of electro-mechanical systems. These hybrid-electric turbine engines provide additional actuation and energy management control opportunities for improving stability and transient response behavior. This paper summarizes the results of a Hardware-in-the-Loop (HIL) test performed at the NASA Electric Aircraft Testbed (NEAT) during the summer of 2022. The test demonstrates the feasibility and performance of an advanced energy management control strategy by integrating a simulated turbofan engine with scaled electro-mechanical hardware. A full-scale real-time reference model of a geared turbofan was run alongside a scaled electro-mechanical system representing the electrified turbofan components operating at a megawatt-scale power level. The model was interfaced with the hardware through a novel closed-loop control and scaling algorithm that emulated the dynamic speed and torque response of the turbofan shafts. The control strategy was implemented on the electrical machines connected to the emulated turbomachinery shafts. The results from the testbed are compared against simulations that predict the testbed and geared turbofan model operation. The energy management control strategy successfully changed the operating point of the engine model and improved its stability during throttle transients. These results also demonstrate the success of the novel closed loop control and scaling approach for emulating turbomachinery and elevate the Technology Readiness Level (TRL) of the energy management control strategy.
Many electrified aircraft configurations consist of a number of power components operating on the same shared electrical bus. Understanding the impedance performance of electrical loads and sources is key to understanding, and designing for, acceptable overall vehicle power quality and power system stability. To enable these measurements, personnel at NASA’s Glenn Research Center have designed and built the Scaled Power ElEctrified Drivetrain (SPEED) Testbed. This paper will present data taken in the SPEED lab, including impedance measurements of a DC supply (source) and a motor drive and electric machine (load) under a number of conditions. Impacts of load power, drive controller tuning, and field-weakening on load impedance are measured, presented, and discussed; as are source impedance data, stability, and DC bus current spectra at different loading levels.
Many electrified aircraft configurations consist of a number of power components operating on the same shared electrical bus. Understanding the impedance performance of electrical loads and sources is key to understanding, and designing for, acceptable overall vehicle power quality and power system stability. To enable these measurements, personnel at NASA’s Glenn research Center have designed and built the Scaled Power ElEctrified Drivetrain (SPEED) Testbed. This paper will present data taken in the SPEED lab, including impedance measurements of a DC supply (source) and a motor drive and electric machine (load) under a number of conditions. Impacts of load power, drive controller tuning, and field weakening on load impedance are measured, presented, and discussed; as are source impedance data, and DC bus current spectra at different loading levels.
Recent advances in technology and a push for more environmentally friendly air transportation has led to interest in electrified aircraft propulsion (EAP). EAP encompasses many different propulsion system architectures which can also enable new, synergistic propulsion-airframe integration approaches. This report evaluates the combination of turboelectric EAP and fuselage boundary layer ingestion (BLI) propulsion in a concept called “STARC-ABL.” The predicted fuel consumption benefits of STARC-ABL are updated from a prior 2016 study with new mission requirements and analysis methodologies. Additionally, certification noise is added to the concept evaluation. To properly assess the impact of EAP, a new concept, “ST-ABL,” is developed for comparison which includes the fuselage BLI propulsor driven mechanically instead of by a turboelectric system. STARC-ABL is predicted to provide a 3.4% reduction in fuel consumption for a single-aisle class, 3500 nmi design mission and a 2.7% reduction for a 900 nmi mission, both relative to an advanced technology conventional aircraft. STARC-ABL is also predicted to have a Chapter 14 cumulative noise margin of 7 EPNdB. The non-EAP ST-ABL concept results in slightly higher fuel consumption and noise than STARC-ABL, indicating that the turboelectric system provides benefits over the mechanical drive approach to fuselage BLI. Areas for future research and evolution of the concept include assessing its applicability to other aircraft sizes, increasing the fidelity of BLI and electric component modeling, and investigating other EAP architecture options.
Electrified Aircraft Propulsion (EAP) concepts could enable various benefits through a variety of use-cases. Benefits are sought in the form of reduced fuel burn and emissions. Many of these concepts involve the electrification of gas turbine engines. Electrification is accomplished through the integration of electric machines (EMs) with the engine shafts, providing the ability to inject and/or extract power as desired. Energy storage is also a common feature. An often-overlooked feature of the analysis is the means of integrating the EMs with the engine shafts. A trivial solution is to allow each shaft to have its own dedicated EM through independent geartrains. However, non-trivial mechanical integration solutions could provide benefits when considered in coordination with control logic to manage the operation of the propulsion system. Here, such a solution is considered and is shown to have the potential to reduce weight for a relevant conceptual electrified propulsion system. Weight saving benefits are demonstrated for various EAP use-cases. In particular, the mild hybrid application was shown to benefit from a power system weight reduction of 47% and an overall system weight reduction of 29%.
Electrified Aircraft Propulsion (EAP) concepts could enable various benefits through a variety of use-cases. Benefits are sought in the form of reduced fuel burn and emissions. Many of these concepts involve the electrification of gas turbine engines. Electrification is accomplished through the integration of electric machines (EMs) with the engine shafts, providing the ability to inject and/or extract power as desired. Energy storage is also a common feature. An often-overlooked feature of the analysis is the means of integrating the EMs with the engine shafts. A trivial solution is to allow each shaft to have its own dedicated EM through independent geartrains. However, non-trivial mechanical integration solutions could provide benefits when considered in coordination with control logic to manage the operation of the propulsion system. Here, such a solution is considered and is shown to have the potential to reduce weight for a relevant conceptual electrified propulsion system. Weight saving benefits are demonstrated for various EAP use-cases. In particular, the mild hybrid application was shown to benefit from a power system weight reduction of 47% and an overall system weight reduction of 29%.
Many electrified aircraft configurations consist of a number of power components operating on the same shared electrical bus. Understanding the impedance performance of electrical loads and sources is key to understanding, and designing for, acceptable overall vehicle power quality and power system stability. This paper discusses impedance measurements made on the NASA Electric Aircraft Testbed (NEAT) Electrical Power System (EPS) at NASA Glenn Research Center. First, an overall discussion of the NEAT facility configuration during testing is presented; then details of the impedance measurement approach and the various testing configurations are discussed. Next, input impedance measurements at NEAT, including sources (DC supplies) and loads (multiple motor drives, electric machines, and resistive load banks, with long interconnecting cable leads), are performed under a number of conditions, and results, including load model comparisons and stability analysis, are presented and discussed.
The purpose of the subject presentation is to expose engineering students at Ohio University to ongoing work being performed by the Intelligent Control and Autonomy Branch (ICAB) at the NASA Glenn Research Center in Cleveland, Ohio. The presentation will start with some introductory material about the organization. This will be followed by an overview of Electrified Aircraft Propulsion (EAP) controls research and the ICAB’s support for the Space Launch System (SLS). One aspect of EAP is the integration of electrical motor/generators and other power systems components with turbine engine technology to create propulsion & power systems for single-aisle aircraft that are more fuel efficient and have lower emissions. The presentation will introduce some of the controls, systems health management, and modeling technologies developed by the ICAB to help realize EAP. NASA’s SLS is a super-heavy-lift launch vehicle that provides the foundation for human exploration beyond Earth’s orbit. The presentation will introduce capabilities developed by the ICAB to support the SLS Mission and Fault Management function which includes capabilities for abort, caution and warning, redundancy management, and safing. The presentation will conclude with information about internships with the NASA and the ICAB.
Many electrified aircraft configurations consist of a number of power components operating on the same shared electrical bus. Understanding the impedance performance of electrical loads and sources is key to understanding, and designing for, acceptable overall vehicle power quality and power system stability. This paper discusses impedance measurements made on the NASA Electric Aircraft Testbed (NEAT) Electrical Power System (EPS) at NASA Glenn Research Center. First, an overall discussion of the NEAT facility configuration during testing is presented. Then, details of the impedance measurement approach and the various testing configurations are discussed. Next, input impedance measurements at NEAT, including sources (DC supplies) and loads (multiple motor drives, electric machines, and resistive load banks, with long interconnecting cable leads), are performed under a number of conditions, and results, including load model comparisons and stability analysis, are presented and discussed.
Specific details including selections of process materials, tooling/fixture setups, and a step-by-step procedure for scaling-up demonstrations of the newly developed potting process, namely vacuum-assisted axial injection potting (VaAIP) have been fully developed for the stator winding of high power density electric motors for the future electrified aircrafts. Various essential pre-trial subtasks identified for the full-scale demonstrations were carried out. To date, optimization of cure condition and thermal stability of the coating epoxy and determination of optimum application conditions and thermal stability of the high temperature encapsulant wax were completed successfully and other subtasks were under way. The efforts to enhance thermal conductivity of the selected potting compound by adding conductive nano fillers such as boron nitride nanosheets (BNNS) have also been advanced. Initially, selection of the best mixing method and procedures was attempted via extensive and systematic experimental design.
As electrified aircraft propulsion (EAP) matures and power electronics, electric machines, and batteries achieve higher power density, the thermal management of these devices becomes ever more critical. In this paper, a heat pipe made from a dielectric ceramic material is proposed, which enables its use in the thermal management of a high frequency filter inductor for an EAP power electronics application. The manufacturing process for the sintered powder wick was developed and its performance characterized. The heat pipe is further experimentally demonstrated via an open evaporator test and shown to behave analogous to a constant conductance heat pipe.