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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.

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31 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

High Performance Metal-Supported SOFC System for Range Extension of Commercial Aviation

The DOE ARPA-E REEACH program [1] has enabled this Phase 1 study that conceptualizes a commercial 154 passenger electric aircraft using renewable aviation fuel for range extension while meeting similar mission performance levels as current commercial aircraft. Commercial aviation accounts for about 2.5% of global CO2 emissions, and close to 5% of overall anthropogenic climate change due to the added accounting of contrail’s effects [2]. The sector has adopted a goal of carbon neutrality by 2050 [3]. 110 nations, and recently the new US administration, have embarked on work to address this important challenge. The US DOE has released a roadmap to enable the further development of sustainable aviation fuel (SAF) in the hopes that it could meet all of aviation’s fuel needs by 2050 [4]. However, SAF fuel price and sufficient future feedstock availability remains a concern [5]. Considering the first commercial biofuel flight demonstration 14 years ago [6] and that SAF still only comprises less than 0.1% of jet fuel use, the question arises as how it can ramp up to 100% use in the next 27 years. One option that has the potential to substantially reduce the need for SAF is to implement light-weight Solid Oxide Fuel Cells (SOFCs) that can efficiently utilize SAF or other sulfur-free hydrocarbon fuels. As opposed to lower temperature PEM (Proton Exchange Membrane) fuel cells that can use high-purity hydrogen, SOFC’s fuels are very flexible, ranging from low cost liquefied natural gas (LNG), renewable liquefied natural gas (RLNG), to SAF, to generate clean electrical power for use in aviation propulsion and auxiliary power units [7] [8]. Research progress is needed to enable SOFCs to achieve 3.0 kW/kg power density, making them viable for aviation [9]. The DOE’s Advanced Research Projects Agency – Energy (ARPA-E) has therefore initiated an aviation SOFC R&D program that is anticipated to dramatically reduce aircraft fuel use though the implementation of “Range Extenders for Electric Aviation with low Carbon and High efficiency” (REEACH) [1] for medium range commercial aircraft. This report summarizes the progress during phase 1 of the REEACH program.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Overview of Potential Hazards in Electric Aircraft Charging Infrastructure

With increasing efforts in electrification of Advanced Air Mobility and electric aircraft, there is a growing need to install new infrastructure to support them. This report highlights potential hazards (non exhaustive) that the installation must be aware of and be prepared to mitigate with increased electrical equipment on site. The hazards can be due to natural causes as well as non natural causes. The report aims to provide starting guidelines for awareness of these hazards and to help plan for mitigation of the same.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

The promise of energy-efficient battery-powered urban aircraft

Improvements in rechargeable batteries are enabling several electric urban air mobility (UAM) aircraft designs with up to 300 mi of range with payload equivalents of up to seven passengers. Novel UAM aircraft consume between 130 Wh/passenger-mi and ∼ 1,200 Wh/passenger-mi depending on the design and utilization, compared to an expected consumption of over 220 Wh/passenger-mi and 1,000 Wh/passenger-mi for terrestrial electric vehicles and combustion engine vehicles, respectively. We also find that several UAM aircraft designs are approaching technological viability with current Li-ion batteries, based on the specific power and energy, while rechargeability and lifetime performance remain uncertain. These aspects highlight the technological readiness of a new segment of transportation.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Safety of Mobile Hydrogen and Fuel Cell Technology Applications: An Investigation by the Hydrogen Safety Panel

Safe practices in the production, storage, distribution, and use of hydrogen are essential for the widespread acceptance of hydrogen and fuel cell technologies. A significant safety incident could damage public perception of hydrogen and fuel cells. Recent incidents involving multi-cylinder hydrogen transport vehicles in the United States have brought attention to the potential impacts of mobile hydrogen storage and transportation. Road transportation of bulk gaseous hydrogen presents unique hazards that can be very different from those for stationary equipment, and new equipment developers may have less experience and expertise than seasoned gas providers. In response to the aforementioned incidents, and in support of hydrogen and fuel cell activities in California specifically, the Hydrogen Safety Panel (HSP) has investigated the safety of mobile hydrogen and fuel cell applications (mobile auxiliary/emergency fuel cell power units, mobile fuelers, multi-cylinder transport vehicles, unmanned aircraft power supplies, and mobile hydrogen generators). The HSP examined the applications, requirements, and performance of mobile applications that are being used extensively outside of California to understand how safety considerations are applied. This report discusses the results of the HSP’s evaluation of hydrogen and fuel cell mobile applications along with recommendations to address relevant safety issues.

08 HYDROGEN↗
DOE OSTI2022

The challenges and opportunities of battery-powered flight

Aircraft, and the aviation ecosystem in which they operate, are shaped by complex trades among technical requirements, economics and environmental concerns, all built on a foundation of safety. This Perspective explores the requirements of battery-powered aircraft and the chemistries that hold promise to enable them. The difference between flight and terrestrial needs and chemistries are highlighted. Safe, usable specific energy rather than cost is the major constraint for aviation. We conclude that battery packs suitable for flight with specific energy approaching 600 kilowatt hours per kilogram may be achievable in the next decade given sufficient investment targeted at aeronautical applications.

25 ENERGY STORAGE↗
DOE OSTI2024

High-Efficiency and Low-Carbon Energy Storage and Power Generation System for Electric Aviation

This report summarizes the work performed by University of California San Diego (UCSD) – Honeywell Aerospace (Honeywell) team for the U.S. Department of Energy/Advanced Research Projects Agency-Energy (DOE/ARPA-E) under Phase 1 (April 2021 – October 2023) project, Cooperative Agreement DE-AR0001347 entitled “High-Efficiency and Low-Carbon Energy Storage and Power Generation System for Electric Aviation”. The main objective of this project is to develop and demonstrate an energy storage and power generation (ESPG) system operating on bio liquid natural gas (LNG) for electric aviation applications. The ESPG system concept in this project is a fuel cell, battery, and gas turbine hybrid system that incorporates an innovative solid oxide fuel cell (SOFC) technology. This SOFC technology has two main novel elements: (i) a lightweight and compact stack architecture that consists of cells and cell modules in electrical parallel and series connections (the module design) and (ii) exceptionally high performance, direct methane thin-film cells on porous substrate made by sputtering deposition process. This fuel cell has the specific power and volumetric power density suitable for electric aviation applications. Based on the current status of the SOFC technology, the Phase 1 work focused on the following activities: (i) ESPG System Modeling – to design and optimize an aircraft SOFC-based ESPG system concept that met the performance, weight and cost targets; (ii) Cell Material Development and Scaleup – to demonstrate scalability of the sputtering process for manufacture of thin-film SOFC cells of practical sizes, confirm the exceptional performance of sputtered cells, improve cell stability and durability for operation with hydrogen and methane fuel, and develop a suitable electrically conducting porous substrate to replace the current non-conducting ceramic substrate; (iii) Stack Development – to design and manufacture stack components for the stack architecture, evaluate and select a suitable sealant, and build and operate multi-cell stacks to demonstrate stack operation, and (iv) Technology to Market – to develop business models and commercialization plans, conduct various market and technology analysis and estimate SOFC and ESPG system costs.

25 ENERGY STORAGE↗
DOE OSTI2024

Next-Generation, High-temperature, High-frequency, High-efficiency, High-power-density Traction System

To meet performance and reliability requirements necessary for broader adoption of electric drive vehicles, the Electrical and Electronics Technical Team of the U.S. Drive partnership has established aggressive design goals for next-generation electric vehicle drivetrains. Specifically, the 2025 roadmap stipulates a 100 kW/L power density target and a $\$$2.7/kW cost target for power electronics, in addition to high-voltage operation (i.e., greater than 800 VDC). The additional targets for traction motor and the overall system performance impose further challenges on the power electronics design. For example, many high specific power machines have reduced iron content, and therefore reduced intrinsic filtering, thus requiring the inverter to supply a low-distortion drive current. These machines also typically have a high pole count, thus requiring drive current at a higher electrical frequency. Other motors, such as brush-less dc and switch reluctance machines, require a carefully-shaped, non-sinusoidal drive current (Yang, Shang, Brown, & Krishnamurthy, 2015), (Zhang, Bowman, O'Connel, & Haran, 2018), (Anderson, et al., 2018). Two- and three-level inverter topologies are the conventional framework for the power electronics design of the drivetrain, and some demonstrations have shown recent progress towards addressing cost, power density and efficiency goals (Gurpinar & Ozpineci, 2018), (Zhu, Kim, Chen, Erickson, & Maksimović, 2018), (Deshpande, Chen, Narayanasamy, Sathyanarayanan, & Luo, 2018), (Alizadeh, et al., 2019). However, an unconventional approach may be necessary to take the dramatic leap in power density necessitated by the roadmap—while simultaneously addressing the other system needs. Therefore, this project leverages the flying capacitor multilevel (FCML) topology, together with a scalable, modular approach, to address these needs. This type of hybrid converter has several advantages: lower voltage (i.e., less than 300 V) transistors can be used, energy-dense capacitors process most of the power, and the output current waveform is multilevel and exhibits a frequency multiplying effect—in other words, the output has reduced dv/dt and filtering requirements for the same high voltage dc bus. For example, in an electric vehicle with an 800 V bus, a 10-level FCML could leverage 100 V, commercially available GaN devices switching at 115 kHz to produce a ~1 MHz switching waveform (modulated according to the motor drive requirements) with one ninth of the dv/dt of a two-level converter. Prior work has already demonstrated promising performance and gravimetric power density figures for more electric aircraft applications (Pallo, Foulkes, Modeer, Coday, & Pilawa-Podgurski, 2018). This project leverages lessons learned to achieve the volumetric power density of 100 kW/L by employing advanced liquid cooling, address the 300,000 mile reliability challenge with redundant design, topology failure studies and online health monitoring, and reduce costs to $\$$2.7/kW through the use of low-cost GaN devices, modular converter assemblies, and modest modifications to traditional manufacturing methods. The project involved several hardware designs, each achieving increasing performance. At the conclusion of the project, a volumetric power density of 380 kW/L was achieved, in a 800V dc-ac converter, greatly surpassing even the aggressive target goal.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Flux-Switching Machine Based All-Electric Power Train for Future Aircraft

This research investigates a flux-switching motor with superconducting and cryogenically cooled windings, aimed at achieving exceptionally high power densities. In addition to the motor’s topology and superconducting windings, it was found that power density could be further enhanced by incorporating superconducting shields on the rotor at the interpole locations. The resulting publications and patented technology outline the design process. A motor power density of 64 kW/kg—including housing materials—was achieved for a 1 MW design, surpassing the performance of existing motors. An electronic drive was also developed, achieving a power density of 47 kW/kg. This includes the mechanical structure of the drivetrain, for which a detailed CAD model was created, resulting in an overall drivetrain power density of 27 kW/kg.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Optimal Managed Fast-Charging Model for Electric Vehicle Fleets with High Utilization and Multiple Charge-Acceptance Curves

A predictive control/scheduling optimization model is proposed for managed charging of an electric vehicle (EV) fleet - under time-of-use energy and demand prices, high vehicle utilization frequency (short dwell times), multiple charge- acceptance curves (configurable charging rates), and flexible vehicle demand. This context is particularly relevant for flight schools (small electric aircraft) or other commercial facilities where an EV fleet performs multiple operating and fast-charging sessions on the same day. The proposed model performs both the operational and charging scheduling of the vehicles, which is not typically done for residential managed charging and significantly increases problem complexity. The problem is formulated as a MILP model and a case study of a small fast-charging station is presented. Results demonstrate a significant reduction in operating cost, mainly from peak shaving during high demand price periods, achieved by coordinating the operation of different vehicles, chargers and charging rates.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2023

Federal Aviation Administration Vertiport Electrical Infrastructure Study

In this detailed analysis, the authors assess the charging infrastructure needed for the deployment of advanced air mobility involving electrified vertical take-off and landing technologies. The report covers four research areas: (1) Identifying charging infrastructure requirements for existing facilities based on flight operational parameters, potential use cases, charging strategy, and other constraints. (2) Assessing sites on power availability to meet charging demand, the impact on grid infrastructure, potential hazards, and cybersecurity needs, and using technoeconomic analysis to identify opportunities for onsite distributed energy resources, primarily solar photovoltaics and battery energy storage systems. (3) Calculating greenhouse gas emission based on total energy consumption attributable to each site. (4) Analyzing the job and economic development impact for sites adopting new infrastructure.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

A Roadmap Toward a Sustainable Aviation Ecosystem

This report outlines a holistic view of pathways to a sustainable aviation ecosystem, focusing on low-net-carbon aircraft energy carriers (fuels), airport ecosystems (airports and bases), and developments in sustainable aircraft components (aircraft). Taking this holistic ecosystem perspective, we identify critical components that contribute to sustainable energy solutions necessary to achieve deep decarbonization of the aviation industry, as well as the integrated energy system interfaces that must be comprehensively understood, planned for, and realized. Further, we outline necessary R&D needs to achieve sustainability across the aviation ecosystem, including advancing breakthrough innovations to rapidly achieve scalable solutions, with attention to their cross-sectoral dependencies and implications.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

An Overview of Potential Future Aviation Energy Carriers

Global jet fuel demand is projected to grow to 165 billion gallons by 2050 and there is growing interest in the aviation industry to understand the capabilities of alternative energy carriers. This report considers several potential energy carriers, reviewing their production potential, operational considerations, and economic implications to inform potential next steps in aeronautics research. The following energy carriers (i.e., fuels) were evaluated in this study for future use in aviation: sustainable aviation fuel (SAF) - both biomass-based and power-to-liquids (PtL) - based SAF - cryogenic hydrogen (LH 2 ) - also known as liquid hydrogen - liquefied natural gas (LNG), liquefied ethane (LE), and Jet X. The barriers and opportunities for the evaluated energy carriers vary. SAF is a commercially available drop-in fuel compatible with existing aircraft and infrastructure. SAF is limited by both higher prices and slow commercialization of multiple pathways using different feedstocks necessary to significantly grow supply. Cryogenic fuels, in contrast, have very different thermal, physical, and chemical properties than SAF and Jet A, requiring the construction of new airport storage and dispensing infrastructure and the design of new aircraft energy systems capable of mitigating heat transfer and boil-off. Cryogenic fuels offer an opportunity to diversify aviation fuel carriers from domestic energy relevant for both energy security and resilience. This means cryogenic fuels are more of a longer-term solution for aircraft but are worth exploring for potential future cost savings and emissions benefits. Jet X refers to non-drop-in liquid hydrocarbon fuels in the early stages of investigation seeking favorable properties. There are substantial barriers to non-drop-in liquid aviation fuels that are not compatible with existing aircraft and fuel infrastructure.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Evaluation of methods for characterizing the fine particulate matter emissions from aircraft and other diffusion flame combustion aerosol sources

The U. S. Environmental Protection Agency in collaboration with the U. S. Air Force Arnold Engineering Development Complex conducted the VAriable Response In Aircraft nvPM Testing (VARIAnT) 3 and 4 test campaigns to compare nvPM emissions measurements from a variety of diffusion flame combustion aerosol sources (DFCASs), including a Cummins diesel engine, a diesel powered generator, two gas turbine start carts, a J85-GE-5 turbojet engine burning multiple fuels, and a Mini-CAST soot generator. The VARIAnT research program has conducted four test campaigns to date with the VARIAnT 3 and 4 test campaigns focusing on BC mass instrument performance, use of gas turbine engine sources for BC mass instrument calibration, and the characterization of the aerosols produced from the combustion sources. Results from both campaigns revealed agreement of about 20% between the AVL Micro-Soot Sensor, the Cavity Attenuated Phase Shift (CAPS PMSSA) monitor and the thermal-optical reference method for elemental carbon (EC), independent of the calibration source used. For the Artium LII-300, the measured mass concentrations in VARIAnT3 fall within 18% and in VARIAnT4 fall within 32% of the reference EC mass concentration when calibrated on a combustor rig in VARIAnT3 and on a LGT-60 start cart in VARIAnT4, respectively. It was also found that the three mass instrument types (MSS, CAPS PMSSA, and LII-300) can exhibit different BC to reference EC ratios depending on the emission source that appear to correlate to particle geometric mean mobility diameter, morphology, or some other parameter associated with particle geometric mean diameter (GMD) with the LII-300 showing a slightly stronger apparent trend with GMD. Systematic differences in LII-300 measured mass concentrations have been reduced by calibrating with a turbine combustion source (combustor or turbine engine). With respect to the particle size measurements made, the sizing instruments (TSI SMPS, TSI EEPS, and Cambustion DMS 500) were found to be in general agreement in terms of size distributions and concentrations with some exceptions. Teflon filter measurements of the total aerosol mass produced by the various DFCASs differed from the reference EC, BC, and integrated particle sized distribution measured aerosol masses. The Teflon filter measured mass was 30 to 40% greater than the reference EC and 50 to 60% greater than the BC mass for the J85 in both test campaigns. The measurements of particle size distributions and single particle analysis by miniSPLAT indicated the presence of large particles (>100 nm) having more compact morphologies, higher effective density, and a composition dominated by OC and ash. This increased large particle fraction is also associated with higher values of single scattering albedo measured by the CAPS PMSSA instrument and higher OC/EC measurements. These measurements indicate gas turbine engine emissions can be a more heterogeneous mix of particle types beyond the original E31 assumption that it is mainly composed of black carbon.

33 ADVANCED PROPULSION SYSTEMS↗