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Electrifying Aircraft Propulsion: Thermal Issues of Megawatt Scale Power Dense Electric Machines and Material Solutions

Aircraft are the last major mode of transportation to undergo electrification for many reasons, where the underlying reason is the sensitivity of aircraft performance to mass. This sensitivity demands that efficient, megawatt (MW)-scale high specific power density powertrains be developed to impact regional, single aisle and larger aircraft that account for the majority of fuel burn in commercial aviation. Developing MW-scale high specific power electric powertrains (machines, cables/busbars and power electronics) remains a significant challenge. While advanced power semiconductors have enabled higher voltages, densities, and operational frequencies this also leads to passing high current through smaller volumes when considering electric machines and power electronics. This poses significant thermal challenges. This is particularly true for electric machines that strive to surpass 13 kW/kg, which studies have shown to be desirable for electric aircraft propulsion. The necessity of handling high current densities to achieve MW power levels dictates that greater than 10kW of waste heat will be generated. Moreover, most of the heat is generated in the stator winding which is a mixture of electrical conductor (copper or aluminum), potting material, magnet wire (electrical) insulation and high voltage electrical insulation. Although the electrical conductor is a fantastic thermal conductor, it is also the source of the heat (carrying the electrical current) and is thermally isolated by the other materials. Simply letting the machine run at increased temperatures is an attractive idea, however the reality is that most of the suitable electric insulations and potting material candidates are not likely to satisfactorily operate at higher temperatures with reasonable life expectancies. The likelihood of developing new polymers that can satisfy the necessary functions (mechanical and electrical), operate at higher temperatures with acceptable lifetime in the near term is small. This has led the researchers at the NASA Glenn Research Center to examine electrically insulative materials in high power destiny electric machines, their thermal environment, and what solutions are realistic from a materials point of view. This presentation will touch on both the thermal challenges of electric machines and NASA Glenn’s research into material solutions.

Electric Aircraft Propulsion↗

Further Research on the Electrification of Pyrocumulus Clouds

Past research on pyrocumulus electrification has demonstrated that a variety of lightning types can occur, including cloud‐to‐ground (CG) flashes, sometimes of dominant positive polarity, as well as small intra‐cloud (IC) discharges in the upper levels of the pyro‐cloud. In Colorado during summer 2012, the first combined polarimetric radar, multi‐Doppler radar, and three‐dimensional lightning mapping array (LMA) observations of lightning‐producing pyrocumulus were obtained. These observations suggested that the National Lightning Detection Network (NLDN) was not sensitive enough to detect the small IC flashes that appear to be the dominant mode of lightning in these clouds. However, after an upgrade to the network in late 2012, the NLDN began detecting some of this pyrocumulus lightning. Multiple pyrocumulus clouds documented by the University of Wisconsin for various fires in 2013 and 2014 (including over the Rim, West Fork Complex, Yarnell Hill, Hardluck, and several other incidents) are examined and reported on here. This study exploits the increased‐sensitivity NLDN as well as the new nationwide U.S. network of polarimetric Next‐generation Radars (NEXRADs). These observations document the common occurrence of a polarimetric "dirty ice" signature ‐ modest reflectivities (20‐40+ dBZ), near‐zero differential reflectivity, and reduced correlation coefficient (less than 0.9) ‐ prior to the production of lightning. This signature is indicative of a mixture of ash and ice particles in the upper levels of the pyro‐cloud (less than ‐20 C), with the ice interpreted as being necessary for pyro‐cloud electrification. Pseudo‐Geostationary Lightning Mapper (GLM) data will be produced from the 2012 LMA observations, and the ability of GLM to detect small pyrocumulus ICs will be assessed. The utility of lightning and polarimetric radar for documenting rapid wildfire growth, as well as for documenting pyrocumulus impacts on the composition of the upper troposphere/lower stratosphere (UTLS), will be discussed.

Lang, Timothy J.↗

Transient Optimization of an Electrified Gas Turbine Engine Using Machine Learning

Gas turbine engines are designed with sufficient margin to prevent stall under normal operating conditions throughout their life. This compromise ensures that during rapid accelerations, compressor operation remains stable, but at the cost of efficiency and thrust responsiveness. The design margin encompasses multiple sources of uncertainty and systematic deviances from the operating line, the largest of which is the transient allowance. This set-aside accounts for the temporary incoordination of the engine spools during an acceleration while still enabling it to meet the certification requirement to accelerate from low to high power within a specified time, and without experiencing overtemperature, surge, stall, or other detrimental factors. Electrification of the powertrain provides the opportunity to address this reserve and truly optimize the design. The addition of electric machines inherent in hybrid propulsion concepts offers a means to interact with the engine shafts such that the necessary margin can be reduced, which can positively impact the engine design. By adjusting the amount of power extracted from or injected to the engine spools by the electric machines during transient operation, excursions from the operating line can be minimized. Past work using a dynamic engine model has shown that optimization of the fuel flow schedule during acceleration can reduce the required margin while still meeting the time requirement, and results are further improved when combined with power injection and extraction. The current work uses machine learning through a genetic algorithm to address the problem holistically by concurrently optimizing the electric machine power command and fuel flow acceleration schedule using an updated, higher fidelity version of the original engine model.

Stall Margin↗

Transient Optimization of an Electrified Gas Turbine Engine Using Machine Learning

Gas turbine engines are designed with sufficient margin to prevent stall under normal operating conditions throughout their life. This compromise ensures that during rapid accelerations, compressor operation remains stable, but at the cost of efficiency and thrust responsiveness. The design margin encompasses multiple sources of uncertainty and systematic deviances from the operating line, the largest of which is the transient allowance. This set-aside accounts for the temporary incoordination of the engine spools during an acceleration while still enabling it to meet the certification requirement to accelerate from low to high power within a specified time, and without experiencing overtemperature, surge, stall, or other detrimental factors. Electrification of the powertrain provides the opportunity to address this reserve and truly optimize the design. The addition of electric machines inherent in hybrid propulsion concepts offers a means to interact with the engine shafts such that the necessary margin can be reduced, which can positively impact the engine design. By adjusting the amount of power extracted from or injected to the engine spools by the electric machines during transient operation, excursions from the operating line can be minimized. Past work using a dynamic engine model has shown that optimization of the fuel flow schedule during acceleration can reduce the required margin while still meeting the time requirement, and results are further improved when combined with power injection and extraction. The current work uses machine learning through a genetic algorithm to address the problem holistically by concurrently optimizing the electric machine power command and fuel flow acceleration schedule using an updated, higher fidelity version of the original engine model.

Stall Margin↗

Transient Optimization of an Electrified Gas Turbine Engine Using Machine Learning

Gas turbine engines are designed with sufficient margin to prevent stall under normal operating conditions throughout their life. This compromise ensures that during rapid accelerations, compressor operation remains stable, but at the cost of efficiency and thrust responsiveness. The design margin encompasses multiple sources of uncertainty and systematic deviances from the operating line, the largest of which is the transient allowance. This set-aside accounts for the temporary incoordination of the engine spools during an acceleration while still enabling it to meet the certification requirement to accelerate from low to high power within a specified time, and without experiencing overtemperature, surge, stall, or other detrimental factors. Electrification of the powertrain provides the opportunity to address this reserve and truly optimize the design. The addition of electric machines inherent in hybrid propulsion concepts offers a means to interact with the engine shafts such that the necessary margin can be reduced, which can positively impact the engine design. By adjusting the amount of power extracted from or injected to the engine spools by the electric machines during transient operation, excursions from the operating line can be minimized. Past work using a dynamic engine model has shown that optimization of the fuel flow schedule during acceleration can reduce the required margin while still meeting the time requirement, and results are further improved when combined with power injection and extraction. The current work uses machine learning through a genetic algorithm to address the problem holistically by concurrently optimizing the electric machine power command and fuel flow acceleration schedule using an updated, higher fidelity version of the original engine model.

Stall Margin↗

Sizing Power Components of an Electrically Driven Tail Cone Thruster and a Range Extender

The aeronautics industry has been challenged on many fronts to increase efficiency, reduce emissions, and decrease dependency on carbon-based fuels. The NASA Aeronautics Research Mission Directorate has identified a suite of investments to meet long term research demands beyond the purview of commercial investment. Electrification of aviation propulsion through turboelectric or hybrid electric propulsion is one of many exciting research areas which has the potential to revolutionize the aviation industry. This paper will provide an overview of the turboelectric and hybrid electric technologies being developed under NASAs Advanced Air Transportation Technology (AATT) Project, and how these technologies can impact vehicle design. An overview will be presented of vehicle system studies and the electric drive system assumptions for successful turboelectric and hybrid electric propulsion in single aisle size commercial aircraft. Key performance parameters for electric drive system technologies will be reviewed, and the technical investment made in materials, electric machines, power electronics, and integrated power systems will be discussed. Finally, power components for a single aisle turboelectric aircraft with an electrically driven tail cone thruster and a hybrid electric nine passenger aircraft with a range extender will be parametrically sized.

turbogenerator↗

Computational Heat Flux Analysis for HEATheR Electric Aircraft Wing Ice Protection Systems

Increased electrification of aircraft systems, a growing trend in the aircraft industry, affects subsystems that have historically been pneumatically driven by the engine. Optimized design of propulsion and power systems must account for the requirements of these subsystems. One such subsystem, the wing ice protection system, is the focus of this paper. A preliminary computational icing analysis has been conducted using the LEWICE and ANSYS FENSAP-ICE software to characterize the requirements of a thermal ice protection system for three More Electric Aircraft concepts. This paper summarizes the methodology, simulation execution, and icing conditions used for the analysis as well as discusses the results, observed trends, and impacts to system design. This initial analysis indicates that the computed heat requirements for the wing ice protection systems are not within the capabilities of known traditional systems. A discussion of potential methods for reducing the heat flow requirement by the ice protection system is included. Potential refinements to the analysis to improve the accuracy are also discussed.

Nic Heersema↗

Lightning Initiation Forecasting: An Operational Dual-Polarimetric Radar Technique

The objective of this NASA MSFC and NOAA CSTAR funded study is to develop and test operational forecast algorithms for the prediction of lightning initiation utilizing the C-band dual-polarimetric radar, UAHuntsville's Advanced Radar for Meteorological and Operational Research (ARMOR). Although there is a rich research history of radar signatures associated with lightning initiation, few studies have utilized dual-polarimetric radar signatures (e.g., Z(sub dr) columns) and capabilities (e.g., fuzzy-logic particle identification [PID] of precipitation ice) in an operational algorithm for first flash forecasting. The specific goal of this study is to develop and test polarimetric techniques that enhance the performance of current operational radar reflectivity based first flash algorithms. Improving lightning watch and warning performance will positively impact personnel safety in both work and leisure environments. Advanced warnings can provide space shuttle launch managers time to respond appropriately to secure equipment and personnel, while they can also provide appropriate warnings for spectators and players of leisure sporting events to seek safe shelter. Through the analysis of eight case dates, consisting of 35 pulse-type thunderstorms and 20 non-thunderstorm case studies, lightning initiation forecast techniques were developed and tested. The hypothesis is that the additional dual-polarimetric information could potentially reduce false alarms while maintaining high probability of detection and increasing lead-time for the prediction of the first lightning flash relative to reflectivity-only based techniques. To test the hypothesis, various physically-based techniques using polarimetric variables and/or PID categories, which are strongly correlated to initial storm electrification (e.g., large precipitation ice production via drop freezing), were benchmarked against the operational reflectivity-only based approaches to find the best compromise between forecast skill and lead-time. Forecast skill is determined by statistical analysis of probability of detection (POD), false alarm ratio (FAR), Operational Utility Index (OUI), and critical success index (CSI).

Woodard, Crystal J.↗

Using Optical Lightning Detection Data from the 2017 GOES-R Post Launch Test Field Campaign Flights as an Evaluation of Convective Processes

The primary mechanisms for thunderstorm electrification and lightning production are widely understood and allow connections between lightning intensity and occurrence to be used to derive storm strength and forecast the probability of related weather phenomena. However, these assumed relationships between lightning and convective properties were discovered primarily using ground-based lightning sensors and measurements, meaning the true depth of insight from space or air based detections is widely unexplored. In 2017, a field campaign was launched to validate the instrumentation aboard the GOES-16 satellite. It involved flying a NASA-ER2 aircraft over multiple storms across the continental US and it included the Fly’s Eye GLM Simulator (FEGS) as a proxy for the Geostationary Lightning Mapper (GLM). Utilizing the data from this field campaign, one of the main goals of this project is to investigate how attributes of convection impact optical lightning detection and the subsequent assumptions that can be made in relation to convective dynamics and precipitation microphysics. Hydrometeor identification, 3D winds retrieval, and additional radar and LiDAR data analysis will be utilized alongside FEGS and interferometer data in order to observe these relationships. This presentation will be to lay out the initial conclusions from our analysis and to explore any new insights or contradictions within our findings.

Kaitlyn Wheeler↗

Results for an Electrified Aircraft Propulsion Design Exploration

An electrified aircraft propulsion (EAP) design exploration study was performed to determine the impact of EAP technologies on a set of regional transport aircraft concepts. A range of aircraft sizes and types were assessed, including 18, 48, and 70 passenger turboprops, as well as 50 and 78 passenger turbofan aircraft configurations. A previous paper discussed the approaches, technology assumptions, and tools used to carry out the design exploration. The study team designed a series of baseline and advanced EAP aircraft concepts based on existing reference aircraft in the fleet. We then conducted a set of parametric trade studies on the EAP aircraft to better understand the design and performance implications of EAP. This paper documents results from the trade studies, including battery weight versus motor size, climb hybrid power versus cruise hybrid power, and range vs. battery specific energy. Assuming a 500 W-hr/kg battery specific energy, the turboprop aircraft demonstrated a significant fuel savings and modest energy savings. The turbofan aircraft demonstrated no fuel or energy benefits from electrification. In addition, operating cost results are presented on the most promising EAP designs. The cost analysis revealed that the EAP aircraft concepts were not competitive with their baselines, mainly due to the additional depreciation and interest cost for the much heavier and more expensive EAP aircraft.

Ty V Marien↗

The Influence of Soil Moisture, Coastline Curvature, and Land-Breeze Circulations on Sea-Breeze Initiated Precipitation

Idealized numerical simulations are performed with a coupled atmosphere/land-surface model to identify the roles of initial soil moisture, coastline curvature, and land breeze circulations on sea breeze initiated precipitation. Data collected on 27 July 1991 during the Convection and Precipitation Electrification Experiment (CAPE) in central Florida are used. The 3D Goddard Cumulus Ensemble (GCE) cloud resolving model is coupled with the Goddard Parameterization for Land-Atmosphere-Cloud Exchange (PLACE) land surface model, thus providing a tool to simulate more realistically land-surface/atmosphere interaction and convective initiation. Eight simulations are conducted with either straight or curved coast-lines, initially homogeneous soil moisture or initially variable soil moisture, and initially homogeneous horizontal winds or initially variable horizontal winds (land breezes). All model simulations capture the diurnal evolution and general distribution of sea-breeze initiated precipitation over central Florida. The distribution of initial soil moisture influences the timing, intensity and location of subsequent precipitation. Soil moisture acts as a moisture source for the atmosphere, increases the connectively available potential energy, and thus preferentially focuses heavy precipitation over existing wet soil. Strong soil moisture-induced mesoscale circulations are not evident in these simulations. Coastline curvature has a major impact on the timing and location of precipitation. Earlier low-level convergence occurs inland of convex coastlines, and subsequent precipitation occurs earlier in simulations with curved coastlines. The presence of initial land breezes alone has little impact on subsequent precipitation. however, simulations with both coastline curvature and initial land breezes produce significantly larger peak rain rates due to nonlinear interactions.

Baker, David R.↗

Climatological Study of the Short-Term Variation of the 0 C, -10 C, and -20 C Altitude Levels over the Florida Spaceport

For evaluation of the potential of cloud electrification, it is necessary to know the altitude of the 0, -10 and -20 degree Celsius levels. Cape Canaveral Air Force Station has recorded balloon launch data back to 1989. In support of rocket launches, often multiple balloons are launched within minutes of each other in the 4-6 hours leading up to launch. In the past, temperature data from sondes was typically available every hour or so through the launch countdown, allowing for frequent updates of these critical temperature thresholds. Recently, launch customers are relying on Jimsphere and wind profiler data that do not have a thermodynamic component in the latter 4-6 hours of a countdown. This study compares the altitude differences of the 0, -10 and -20 degree Celsius levels from consecutive balloon pairs not to exceed 6 hours apart. The analysis uses 9685 soundings from 1989 to 2013. Approximately 5 of the time the altitude of the temperature level in question (0, -10, -20 degrees C), varies by more than 500 feet (operationally significant threshold) within 6 hours. This study analyzes the altitude variability as a function of several meteorological parameters, such as change in sonde type, dew point depression, and solar zenith angle. Additionally, the study concludes with impacts to launch operations.

Huddleston, Lisa L.↗

Lightning Optical Pulse Statistics from Storm Overflights During the Altus Cumulus Electrification Study

The Altus Cumulus Electrification Study (ACES) was conducted during the month of August, 2002 in an area near Key West, Florida. One of the goals of this uninhabited aerial vehicle (UAV) study was to collect time resolved optical pulse data from thunderstorms. During the month long campaign, we acquired 5294 lightning generated optical pulses. Most of these observations were made while close to the top of the storms. We divided our data into two amplitude groups based on prior NASA U2 aircraft optical data and our pulse characteristics. The group of large pulses with radiance greater than 2.1 mW /sq m sr had mean and median 10 - 10% optical pulse widths of 765 and 735 microns respectively, the 50-50% pulse widths of 396 and 355 microns respectively, and 10-90% rise times of 290 and 260 microns. These values are very similar to the previous U2 based optical results The other group of pulses consisting of slightly more than a quarter of the total pulses observed had radiances less than the minimum values detected in the U2 study. The small pulses were narrower than the large pulses with 5040% mean and median values of 198 and 160 ps respectively. Only 12 % of the flashes contained only small pulses, minimizing the impact of this data on the estimates of detection efficiencies of the orbital instruments, the Lightning Imaging Sensor and Optical Transient Detector.

Mach, D. M.↗

Climatological Study of the Short-Term Variation of the 0 C, -10 C, AND -20 C Altitude Levels Over the Florida Spaceport

For evaluation of the potential of cloud electrification, it is necessary to know the altitude of the 0, -10 and -20 degree Celsius levels. Cape Canaveral Air Force Station has recorded balloon launch data back to 1989. In support of rocket launches, often multiple balloons are launched within minutes of each other in the 4-6 hours leading up to launch. In the past, temperature data from sondes was typically available every hour or so through the launch countdown, allowing for frequent updates of these critical temperature thresholds. Recently, launch customers are relying on jimsphere and wind profiler data that do not have a thermodynamic component in the latter 4-6 hours of a countdown. This study compares the altitude differences of the 0, -10 and -20 degree Celsius levels from GPS-tracked consecutive balloon pairs not to exceed 6 hours apart. The analysis uses 3,198 soundings from 2001 to 2013. Approximately 20, 17, and 13 percent of the time the altitude of the temperature level in question (0, -10, -20 degrees C respectively), varies by more than 500 feet (operationally significant threshold) within 6 hours. This study analyzes the altitude variability as a function of several meteorological parameters, such as dew point depression and solar zenith angle. Additionally, the study concludes with impacts to launch operations.

altitude of 0 degree C temperature level↗

Hybrid Electric Aircraft Thermal Management: Now, New Visions and Future Concepts and Formulation

The global fuel consumption by commercial airlines has increased each year since 2009 and is predicted to reach an all-time high of 97 billion gallons in 2019. There is also an environmental impact from this: CO2 emissions from commercial passenger and freight operations totaled 918 Mt in 2018 (ICCT, 2019), or around 2.5% of global energy-related CO2 emissions. Passenger transport accounted for 81% of the total. Emissions from aviation have grown 32% over the past five years. Coupled with this aspect, there is a continuous and growing need to satisfy ever-growing electrical power needs on commercial and military aircraft. All the armed services (Army, Navy, and Air Force) are continuously trying to enhance UAV (unmanned aerial vehicle) endurance and range across a broad fleet of different aircraft. The commercial Boeing 787 requires about 1.2MWe and that is expected to grow. Current technologies used to supply increased on-board electrical power are generally: 1) “burn more fuel and convert through on-board generators” and 2) use additional heavy (i.e., weight-inefficient) and sometimes unsafe battery systems on-board the aircraft. The aircraft industry is seeking new, innovative ways to satisfy this increasing power demand. One as-yet-untapped power source is the enormous amount of “waste” thermal energy flowing out the jet engine exhaust; some estimates in smaller “by-pass” flow jet engines is several hundreds of kilowatts (e.g., Pratt & Whitney Canada PW545B turbofan). This quantity is much higher in large jet engines associated with commercial aircraft. This large waste thermal energy manifests itself in large temperature differences within the by-pass-flow engine exhaust system relative to outside ambient conditions, because of the actual by-pass engine design configuration. There is strong need to develop thermal technologies and systems that could harness and convert at least a portion of this thermal energy into useful electrical energy to satisfy growing on-board electrical needs. In addition, there is a strong desire within the aircraft and engine manufacturing community to reduce the “carbon footprint” of the industry though reduced fuel usage worldwide. NASA has a robust aircraft electrification program to meet these desires and support industry in its aircraft electrification objectives. This program is integrating thermoacoustic systems, advanced lightweight heat exchanger technology, and advanced heat pipe technology to capture and transport large amounts of engine waste thermal energy for on-board power conversion, advanced heat-pump cooling, and exergy enhancement (i.e., temperature lift). Advanced lightweight heat exchangers are envisioned to capture engine exhaust thermal energy at approximately 673 K and deliver it to efficient thermoacoustic power conversion systems operating at temperature ratios (Thot/Tcold) > 1.6. Advanced heat pipe systems are envisioned to transport thermal energy from low temperature sources, through thermoacoustic heat pumps, to high temperature needs such as wing anti-icing, fuel pre-heating, and combustion air pre-heating. The paper will discuss the current state-of-the-art, objectives, system design architecture, and remaining technical challenges in system formulation within the NASA aircraft electrification program.

Dyson, Rodger↗

The Discharging of Roving Objects in the Lunar Polar Regions

In 2007, the National Academy of Sciences identified the lunar polar regions as special environments: very cold locations where resources can be trapped and accumulated. These accumulated resources not only provide a natural reservoir for human explorers, but their very presence may provide a history of lunar impact events and possibly an indication of ongoing surface reactive chemistry. The recent LCROSS impacts confirm that polar crater floors are rich in material including approx 5%wt of water. An integral part of the special lunar polar environment is the solar wind plasma. Solar wind protons and electrons propagate outward from the Sun, and at the Moon's position have a nominal density of 5 el/cubic cm, flow speed of 400 km/sec, and temperature of 10 eV (approx. equal 116000K). At the sub-solar point, the flow of this plasma is effectively vertically incident at the surface. However, at the poles and along the lunar terminator region, the flow is effectively horizontal over the surface. As recently described, in these regions, local topography has a significant effect on the solar wind flow. Specifically, as the solar wind passes over topographic features like polar mountains and craters, the plasma flow is obstructed and creates a distinct plasma void in the downstream region behind the obstacle. An ion sonic wake structure forms behind the obstacle, not unlike that which forms behind a space shuttle. In the downstream region where flow is obstructed, the faster moving solar wind electrons move into the void region ahead of the more massive ions, thereby creating an ambipolar electric field pointing into the void region. This electric field then deflects ion trajectories into the void region by acting as a vertical inward force that draws ions to the surface. This solar wind 'orographic' effect is somewhat analogous to that occurring with terrestrial mountains. However, in the solar wind, the ambipolar E-field operating in the collision less plasma replaces the gradient in pressure that would act in a collisional neutral gas. Human systems (roving astronauts or robotic systems created by humans) may be required to gain access to the crater floor to collect resources such as water and other cold-trapped material. However, these human systems are also exposed to the above-described harsh thermal and electrical environments in the region. Thus, the objective of this work is to determine the nature of charging and discharging for a roving object in the cold, plasma-starved lunar polar regions. To accomplish this objective, we first define the electrical charging environment within polar craters. We then describe the subsequent charging of a moving object near and within such craters. We apply a model of an astronaut moving in periodic steps/cadence over a surface regolith. In fact the astronaut can be considered an analog for any kind of moving human system. An astronaut stepping over the surface accumulates charge via contact electrification (tribocharging) v.lith the lunar regolith. We present a model of this tribo-charge build-up. Given the environmental plasma in the region, we determine herein the dissipation time for the astronaut to bleed off its excess charge into the surrounding plasma.

Jackson, T. L.↗