Search NASA⌕ Search

SEARCH · Search NASA

Results for “aircraft engine performance”

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.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Measuring the robustness of predictive probability for early stopping in two-group comparisons

We report physical experiments are often expensive and time-consuming. Test engineers must certify the compatibility of aircraft and their weapon systems before they can be deployed in the field, but the testing required is time consuming, expensive, and resource limited. Adopting Bayesian adaptive designs is a promising way to borrow from the successes seen in the clinical trials domain. The use of predictive probability (PP) to stop testing early and make faster decisions is particularly appealing given the aforementioned constraints. Given the high-consequence nature of the tests performed in the national security space, a strong understanding of new methods is required before being deployed. Although PP has been thoroughly studied for binary data, there is less work with continuous data, where many reliability studies are interested in certifying the specification limits of components. A simulation study evaluating the robustness of this approach indicates early stopping based on PP is reasonably robust to minor assumption violations, especially when only a few interim analyses are conducted. The simulation study also compares PP to conditional power, showing its relative strengths and weaknesses. A post-hoc analysis exploring whether release requirements of a weapon system from an aircraft are within specification with desired reliability resulted in stopping the experiment early and saving 33% of the experimental runs.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Relationship of Chemical Composition and Moisture Sensitivity in LiNi x Mn y Co 1-x-y O 2 for Lithium-Ion Batteries

Chemical composition–moisture sensitivity relationship of LiNi x Mn y Co 1-x-y O 2 (NMC) cathode materials was investigated by exploring crystal structures, surface properties, and electrochemical performance behaviors of various commercial NMC powders: LiNi 1/3 Mn 1/3 Co 1/3 O 2 (NMC111), LiNi 0.5 Mn 0.3 Co 0.2 O 2 (NMC532), LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622), and LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811). The NMC powders were stored in different moisture conditions: moisture-free, humidified air, or immersed in water. Rietveld refinement analysis of X-ray diffraction (XRD) data and scanning electron microscopy (SEM) were used to characterize the crystal structure changes and the evolution of particle surfaces morphologies. The effect of moisture contamination on the electrochemical properties of NMC cathodes was studied by galvanostatic cycling and electrochemical impedance spectroscopy (EIS). The moisture contamination resulted in either structural disorder or unwanted surficial deposition products, which increased a charge-transfer impedance and consequent performance degradation of battery cells. The results showed that NMC’s moisture vulnerability increased with Ni content (x) despite protective coatings on commercial particles, which stressed the necessity of alternative surface passivation strategies of Ni-rich NMC for broad applications such as electric vehicles and electrified aircraft propulsion.

25 ENERGY STORAGE↗
DOE OSTI2022

Deceptive Infusion of Data: A Novel Data Masking Paradigm for High-Valued Systems

This work addresses how analysts of a high-valued system (e.g., nuclear reactor, aircraft turbine designs) can extract findable, accessible, interoperable, and reusable scientific data for public dissemination to artificial intelligence and machine-learning (AI/ML) researchers in a manner that cannot be reverse-engineered, potentially compromising sensitive or proprietary information. State-of-the-art methods address this problem through data masking techniques, which allow access to a subset of the information while obfuscating private and potentially identifying information (e.g., personally identifying medical data). These methods are unsuitable for industrial engineering processes, where AI/ML tools need explicit access to all the data available to draw the best inference about the system to help optimize its performance and identify its vulnerabilities, etc. Our novel deceptive infusion of data paradigm provides a solution to this conundrum by developing a mathematical approach capable of concealing the identity of the system while providing full access to all the features employed by AI/ML tools to ensure their optimal performance.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

High temperature thick film sensor development based on doped lanthanum chromites refractory semiconductors materials

High temperature advanced sensing materials have generated high demand due the high accuracy temperature measurements requirements for process optimization, controlling and sensing. Some technological applications of harsh conditions sensing include monitoring tiles of space shuttles, rotating bearings in aircraft engines, turbines, jet engines dynamics and chemical reactors. High temperature conditions limit the sensing strategies, where typically traditional metal thermocouples are unstable, and the sensing options are limited to optical spectroscopy methods. Recently, refractory semiconductors thick- and thin-film thermocouples have been developed and, in many cases, preferred over conventional metallic thermocouples due their spatial resolution, and capability of direct deposition on any surface. Rare earth chromites ceramics materials, exhibit some properties of interest for high temperature sensing technologies development, such as: high microstructure and sintering stability, excellent conductive behavior at high temperatures, and matching thermal expansion coefficients relative to other conductors and refractory ceramics. In this work, high performance ultra-high temperature thermocouples using p-type and n-type doped lanthanum chromites materials were fabricated and tested at temperatures up to 1500 o C. Thermoelectric voltage, Seebeck Coefficients were established for all devices, evidencing high stability and performance in prolongated operational time and harsh conditions.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Fuel cells for single-aisle regional aircraft: System configuration, performance and cost

A hydrogen fuel cell propelled electric aircraft can compete with incumbent turbofan technologies for single-aisle regional aircraft by coupling design of stack, air handling, thermal management, propulsion, and airframe to optimize performance. The stack operates at 95°C to facilitate heat rejection during take-off and below 75°C during cruise to extend lifetime and is oversized to satisfy power requirements at end of life. A multi-stage turbocompressor with a compression ratio >10 is selected to reach high stack power density at 11,300-m cruise altitude. The propulsion system is configured to accommodate air handling within the core duct, an inclined heat exchanger in the outer duct to limit the nacelle size, and variable area nozzles to independently control mass flows through the core and bypass ducts. The airframe is modified for maximum lift coefficient and longer balanced field length for dramatically reduced thrust during take-off, and the fuselage is stretched by 20% to store liquid hydrogen (LH 2 ). Modularization of power systems promotes safety in one engine inoperative scenarios and allows reaching specific power metrics for stack, balance-of-plant and fuel cell system (FCS), necessary for acceptable take-off weight. In conclusion, cost parity requires increase in FCS lifetime, LH 2 cost reduction, and improved FCS specific power.

Catalyst durability↗
DOE OSTI2021

Investigation of grid-based vorticity-velocity large eddy simulation off-body solvers for application to overset CFD

Accurately predicting unsteady wakes and vortex-dominated flows is essential to a wide range of engineering applications, including aircraft, rotorcraft, shipboard operations, bio-inspired unsteady flight and propulsion, wind turbines, and urban flows. While current CFD software can model the complete flow field and wake system, the computational costs incurred in high Reynolds number unsteady turbulent flow simulations often remain prohibitive for routine engineering use, particularly for applications involving moving components. Prior work has demonstrated that by adopting a vorticity-velocity formulation in a grid-based off-body flow solver (VorTran-M and VorTran-M2) one can lower these costs by several orders of magnitude when compared to conventional approaches. This paper describes the extensions made to VorTran-M2 to support turbulent flows, and associated benchmarking activity to assess its performance for problems involving strong stretching and diffusion processes, whose competing contributions to the vorticity field are core drivers of turbulent flow evolution. Predictions are presented for: (i) the Kida-Pelz problem whose inviscid form is of mathematical interest due to its apparent formation of singular flow in finite time; and (ii) the Taylor Green vortex arrangement, which has been extensively studied as a fundamental simulation challenge in the turbulent modeling community. Here, the results are used to evaluate the overall predictive ability and performance of two sub-grid scale models incorporated into VorTran-M2. Results indicate that the computational cost savings seen previously for inviscid and convection dominated problems extend to turbulent flow simulations supporting the viability of VorTran-M2 as a low cost means for accurately modeling the far-field and background flow, particularly when long duration vorticity evolution is of interest.

42 ENGINEERING↗
DOE OSTI2021

Demo 5: RapidClave Technology Demonstrations – Round II (Task 2)

The purpose of this project task was to make automotive composite part manufacturing more cost competitive for low volume production and thereby drive composite application innovation. The strategy was to incorporate low-cost preforming, snap cure resins, and RapidClave® processing to create an alternative to conventional automotive composite manufacturing based on SMC. The program used RapidClave® technology from Globe Machine Manufacturing, fast-curing (“snap cure”) epoxy resins from Hexion, and conformable/stretchable glass fiber reinforcement mats produced by Owens Corning for rapid preforming. O’Gara Armoring retrofits vehicles to meet special security needs, such as larger doors to facilitate easier entry into the vehicle. O’Gara has a variety of custom vehicles in need of custom doors that require affordable tooling to produce approximately 100 ship sets/year. The project focused on a composite door panel application provided by O’Gara that is currently made by manual chopped fiber spray-up processing. UDRI reverse-engineered the current composite door panel and created tooling for use in the RapidClave®. UDRI designed an improved composite door using MultiMat fiberglass reinforcement from Owens Corning. UDRI made snap cure resin films from Hexion resin. Finally, UDRI conducted molding trials to compare autoclave processing with RapidClave® processing. The technical goals of the project were to reduce tooling cost by 50% as compared to SMC compression molding and to reduce cycle time by 50% compared to current manual spray-up process. The approach to reduce tool costs is based on use of single sided tooling for use at 100 psi, as compared to matched metal SMC tooling. An added benefit realized from the program is that the Owens Corning mat provided more uniform thickness and improved performance. Tensile and flexural strengths and moduli were increased by at least 50%. This task also demonstrated a 75% decrease in cycle time. O’Gara is evaluating the technology demonstrated in this project for some of their current production. Additionally, there are new products O’Gara is pursuing which require higher production rates than their current products. O’Gara has identified these new products as good candidates for the RapidClave® technology. The cost advantages demonstrated by this project would then lead to significant economic development. In conclusion, this task successfully combined the RapidClave® technology from Globe with a snap cure epoxy resin film system from Hexion and preform material from Owens Corning. Further research is needed to better map the technical limits such as cycle time of these technologies. Additionally, the technology should be extended in terms of size and shape to include large parts outside of automotive applications, such as a small aircraft fuselage.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A rotorcraft in-flight ice detection framework using computational aeroacoustics and Bayesian neural networks

Abstract This work develops a novel ice detection framework specifically suitable for rotorcraft using computational aeroacoustics and Bayesian neural networks. In an offline phase of the work, the acoustic signature of glaze and rime ice shapes on an oscillating wing are computed. In addition, the aerodynamic performance indicators corresponding to the ice shapes are also monitored. These performance indicators include the lift, drag, and moment coefficients. A Bayesian neural network is subsequently trained using projected Stein variational gradient descent to create a mapping from the acoustic signature generated by the iced wings to predict their performance indicators along with quantified uncertainty that is highly important for time- and safety-critical decision-making scenarios. While the training is carried out fully offline, usage of the Bayesian neural network to make predictions can be conducted rapidly online allowing for an ice detection system that can be used in real time and in-flight.

42 ENGINEERING↗
DOE OSTI2025

Turbulent Parameters by airborne measurements over BNF in March 2025

The original data were collected during the AAF Engineering Flights (AEF2025) in the vicinity of the ARM Bankhead National Forest (BNF) Atmospheric Observatory (https://www.arm.gov/capabilities/observatories/bnf ) in northwestern Alabama in March 2025. The ARM Aerial Facility ArcticShark uncrewed aerial system (UAS, https://www.arm.gov/capabilities/observatories/aaf/uas) was based at the public-use airport of Posey Field, Alabama (FAA LID: 1M4, 34.28027778° N, 87.60055556° W, 283m MSL) from March 10 through March 24, 2025. The ArcticShark UAS performed nine flights, including eight research flights over the AMF3 (BNF Main Site) and Supplemental Facilities to measure atmospheric state, turbulence, surface IR temperature and imagery, and aerosol number concentration and size distribution. The current data set presents a collection of turbulent parameters in the atmospheric boundary layer or lower free troposphere based on airborne measurement throughout the field campaign. The primary instruments used to create the current data set were the Aircraft Integrated Meteorological Measurement System (AIMMS-30) and the fine-wire thermocouple probe.

Atmosphere↗
DOE OSTI2025

Fast Response Temperature by airborne measurements over BNF

The original data were collected during the AAF Engineering Flights (AEF2025) in the vicinity of the ARM Bankhead National Forest (BNF) Atmospheric Observatory (https://www.arm.gov/capabilities/observatories/bnf ) in northwestern Alabama in March 2025. The ARM Aerial Facility ArcticShark uncrewed aerial system (UAS, https://www.arm.gov/capabilities/observatories/aaf/uas) was based at the public-use airport of Posey Field, Alabama (FAA LID: 1M4, 34.28027778° N, 87.60055556° W, 283m MSL) from March 9 through March 24, 2025. The ArcticShark UAS performed nine flights, including eight research flights over the AMF3 (BNF Main Site) and Supplemental Facilities to measure atmospheric state, turbulence, surface IR temperature and imagery, and aerosol number concentration and size distribution. The current data set presents fast response temperature in the atmospheric boundary layer and lower free troposphere measured on the airborne platform throughout the field campaign. The primary instruments used to create the current data set were the fine wire thermocouple probe, the Aircraft Integrated Meteorological Measurement System (AIMMS-30), the Pitot-static system (part of UAS flight control), and the infrared gas analyzer sensor for H2O and CO2 (LI-840). All parameters used in temperature calculations (static pressure, True Air Speed, and absolute humidity in form of dew point temperature) were included in the data set. For user convenience, one additional parameter was also included: the type of flight flag (level, up, down, turn, and combination of thereof).

Air temperature, fast response↗
DOE OSTI2020

Performance Limits for Maritime Wide-Area Search (MWAS) Radar

One of the earliest applications for radar was to search for and find maritime vessels on the open sea. Proper design and operation of an airborne Maritime Wide Area Search (MWAS) radar requires an understanding of system performance characteristics and limitations, and furthermore understanding the trades amongst a large number of interdependent system parameters. This report identifies and explores those characteristics and limits, and how they depend on hardware system parameters and environmental conditions. Ultimately, this leads to a characterization of parameters that offer optimum performance for the overall MWAS radar system. While the information herein is not new to the literature, its collection into a single report hopes to offer some value in reducing the 'seek time'. Acknowledgements This report was funded by General Atomics Aeronautical Systems, Inc. (GA-ASI) Mission Systems under Cooperative Research and Development Agreement (CRADA) SC08/01749 between Sandia National Laboratories and GA-ASI. General Atomics Aeronautical Systems, Inc. (GA-ASI), an affiliate of privately-held General Atomics, is a leading manufacturer of Remotely Piloted Aircraft (RPA) systems, radars, and electro-optic and related mission systems, including the Predator/Gray Eagle-series and Lynx Multi-mode Radar. -

42 ENGINEERING↗
DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
DOE OSTI2023

Chapter 13: All-Electric Vertical Take-Off and Landing Aircraft (eVTOL) for Sustainable Urban Travel

Increasing urbanization, ground congestion, and greenhouse gas emissions have spurred aircraft pioneers to capitalize on advancements in battery technology, electric motors, software, and other advances to develop all-electric vertical take-off and landing (eVTOL) aircraft intended to save travelers time within densely populated urban regions. This study served as an example for conducting a life-cycle analysis (LCA) of an eVTOL aircraft, analyzing its manufacturing process, its in-life operation as a passenger transportation service between urban locations, and (in part) end-of-life treatment. This case study aims to provide guidance on how to accurately conduct eVTOL LCA, particularly on how to define the problem, how to obtain the right information from engineers inside and outside their own organizations, and what areas to focus on. As LCA results are only as accurate as the assumptions that were made, a more rigorous LCA that includes sensitivity analysis and uncertainty characterization can help further understand the limitations of those assumptions. New technologies such as blockchain may also play an important role in LCA, including the life-cycle inventory and improving confidence intervals. Completing a credible LCA is central to supporting the argument in favor of introducing the new technology. Completing such a study will allow companies to demonstrate to relevant stakeholders the likely impact of their aircraft on the environment by quantifying the operational climate footprint of the aircraft and the manufacturing process used to build it. To this end, this case study also provides examples of how to report and present LCA results, optimizing for communications to non-LCA experts. The LCA can also assist in identifying opportunities to improve the environmental performance at various life-cycle stages, informing decision makers as products and manufacturing processes evolve or are redesigned. Given the nascency of both eVTOL aircraft manufacturing and operations, it is strongly recommended that LCA analysts treat reports on eVTOL aircraft as works-in-progress. As new information is found, design changes are made, and the aircraft or operation gains maturity, it is inevitable that some amendments will need to be made to the LCA. It is suggested that a complete overhaul of the LCA be made every 18-24 months throughout the R&D, design, and operational scale-up phases of the project.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Drone Fleet Summary: NNLEMS UxS Rolodex entry for Sandia

Sandia’s UAS Aviation Operations Unit (UAOU) was established in 2019 to be the single entity at Sandia conducting UAS Ops in support the labs Uncrewed Aircraft Systems (UAS) activities. The UAOU currently consists of >330 FAA Registered UAS with a large variety of primarily Class 1&2 UAS: fixed wing (>90), multi-rotor (>230), hybrids, VTOLs, jets, and balloons. Many of these are threat vehicles presented as targets to Counter-UAS (CUAS) systems as part of performance tests, with the remainder in support of other projects across Sandia often with custom payload needs. The UAOU has ~15 primary pilots and reach back to another ~45 FAA Certified Remote Pilots across Sandia. The team conducts flight and CUAS operations at many test locations, including OCONUS. Sandia was awarded the 2024 DOE Federal Aviation Safety Program Award.

42 ENGINEERING↗
DOE OSTI2023

Cooling Strategies for an Electric Motor with Additively Manufactured Hollow Conductors and Distributed Power Electronics Integrated with Heat Pipes

This paper discusses design tradeoffs and thermal modeling explored in cooling strategies for an aircraft propulsion electric motor with additively manufactured coils and distributed power electronics integrated with heat pipes. Design tradeoffs include heat pipe Qmax performance related to inclination, condenser configuration, coolant type, coolant flow path complexity, and ease of access to modular power electronics. Three cooling strategies were selected and realized into CAD models. These models were further evaluated using 3D thermal FEA and optimization tools to explore cooling geometry details that include fin thickness, spacing and count with the objective to minimize fin mass under a set of constraints. Lastly, motorette test data is presented comparing air versus liquid cooling of heat pipes.

additive manufacturing↗
DOE OSTI2021

Performance Evaluation of Comparative Vacuum Monitoring and Piezoelectric Sensors for Structural Health Monitoring of Rotorcraft Components

The costs associated with the increasing maintenance and surveillance needs of aging structures are rising at an unexpected rate. Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today’s extensive fleet of aging aircraft and space vehicles. Aircraft maintenance and repairs represent about a quarter of a commercial fleet’s operating costs. The application of Structural Health Monitoring (SHM) systems using distributed sensor networks can reduce these costs by facilitating rapid and global assessments of structural integrity. The use of in-situ sensors for real-time health monitoring can overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. The ease of monitoring an entire on-board network of distributed sensors means that structural health assessments can occur more often, allowing operators to be even more vigilant with respect to flaw onset. SHM systems also allow for condition-based maintenance practices to be substituted for the current time-based or cycle-based maintenance approach thus optimizing maintenance labor. The Federal Aviation Administration has conducted a series of SHM validation and certification programs intended to comprehensively support the evolution and adoption of SHM practices into routine aircraft maintenance practices. This report presents one of those programs involving a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Sikorsky, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp., Acellent Technologies Inc., and the Federal Aviation Administration (FAA) carried out a trial validation and certification program to evaluate Comparative Vacuum Monitoring (CVM) and Piezoelectric Transducers (PZT) as a structural health monitoring solution to specific rotorcraft applications. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM and PZT systems into rotorcraft maintenance programs and the document revisions necessary to allow for their routine use as an alternate means of performing periodic structural inspections. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically relevant experimental effort to quantify the reliability of a CVM system applied to Sikorsky S-92 fuselage frame application and a PZT system applied to an S-92 main gearbox mount beam application. The applications included both local and global damage detection assessments. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for SHM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and is acceptable to both the aviation industry and regulatory bodies. The validation work completed in this program demonstrated the ability of both CVM and PZT SHM systems to detect cracks in rotorcraft components. It proved the ability to use final system response parameters to provide a Green Light/Red Light (“GO” – “NO GO”) decision on the presence of damage. In additional to quantifying the performance of each SHM system for the trial applications on the S-92 platform, this study also identified specific methods that can be used to optimize damage detection, guidance on deployment scenarios that can affect performance and considerations that must be made to properly apply CVM and PZT sensors. These results support the main goal of safely integrating SHM sensors into rotorcraft maintenance programs. Additional benefits from deploying rotorcraft Health and Usage Monitoring Systems (HUMS) may be realized when structural assessment data, collected by an SHM system, is also used to detect structural damage to compliment the operational environment monitoring. The use of in-situ sensors for health monitoring of rotorcraft structures can be a viable option for both flaw detection and maintenance planning activities. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM and PZT technology. It will also streamline future regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
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 OSTI2021

A Compact 50kW High Power Density, Hybrid 3-Level Paralleled T-type Inverter for More Electric Aircraft Applications

The demand for high performing, lightweight, reliable inverters, increased the scope of wide bandgap and high-switching frequency based solutions. To achieve such high efficiency inverters, it is vital to focus on the system level design considerations to maximize the benefits of these advanced technologies. This paper presents an improved design based on considerations to further reap the benefits of choosing the right inverter topology; increased capabilities through paralleling devices, with reduced total number of switches; and designing a planarized inverter with PCB based busbar. Appropriate thermal analysis and heatsink design has aided in increased system power density along with the overall efficiency. Demonstration of a 50kW 3-phase 3-level paralleled T-type SiC inverter operating at 40kHz switching frequency for aircraft applications is shown to evaluate the benefits of proposed design methodology. Here, the prototype achieves a high power density of 11kW/L.

42 ENGINEERING↗