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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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Materials illustrating a presentation on all-electric aircraft propulsion systems are presented. Propulsion system impacts on aircraft design and areas requiring further study are outlined.
Recent developments in all-electric aircraft technology are reviewed with particular attention given to models with a digital fly-by-wire quadraplex control systems and experimental mechanical actuators. It is shown that all-electric technologies can eliminate many traditional design constraints and open up enormous range of design possibilities.
Review of electrical power systems on existing commercial aircraft
Overview of materials research activities for high voltage electric aircraft propulsion power transmission cables. The overview includes briefing materials research in CNT/Cu composite conductors, micro- multilayered multifunctional electrical insulation (MMEI) and development of high voltage testing capabilities.
Advanced Cooling Technologies, Inc. (ACT) is collaborating with NASA Glenn Research Center (GRC) to develop a heat pipe-based thermal delivery system to efficiently manage the waste heat generated onboard an electric aircraft. The heat pipe system will interface with NASA GRC’s thermoacoustic heat pump in order to recycle waste heat by transporting thermal energy to various end users onboard the aircraft. This paper discusses the layout of theoretical heat pipe networks for a MW-class commercial electric aircraft. This is followed by a discussion of progress made on the development of a novel two-phase heat transport system with solid-state thermal switching and control capabilities.
Li-Air batteries are a unique fit for electric aircraft due to their high theoretical energy densities and their potential to leverage on-board oxygen systems. Electrolytes are the limiting factor for advancing this technology. We will investigate novel "electrolyte engineering" concepts to enable Li-Air batteries with high practical energy densities, rechargeability and safety. New stable electrolytes will be designed and fabricated for Li-Air batteries and tested in an electric flight. An unprecedented "Dream Team" of experts from NASA, DOE, academia and industry will tackle this problem.
NASA has been making investments since ~2015 in technologies related to electric aircraft propulsion. These investments span all-electric with our four passenger X-plane and electric vertical lift studies, to regional flight demonstrators and targeted technology maturation programs. These latter two areas are focused ultimately on reducing fuel burn and overall energy use in transport-class aircraft, with the goal of reducing carbon impact of aviation on our planet. Key technology contributions include such as electric machines, power electronics, cables/bus bars, fault management systems, controls and systems studies, and enabling materials. Today we are seeing the fundamental technology investments manifest themselves in flight demonstrations, that are aimed at impacting aircraft entering service 2035-2040 time range. These efforts have largely been aimed at megawatt scale technologies that can enable hybrid electric or mildly distributed airplane concepts. While these concepts offer benefits to regional and single isle aircraft it is thought that a more fully electrified propulsion system requiring greater than 10 MW of distributed power offers more possible pathways to configure the propulsion-airframe system to gain new efficiencies. A few examples of this are NASA’s SUSAN distributed electrofan concept and NASA University Leadership Initiatives such as CHEETA and IZEA that champion turbo-electric concepts. These concepts utilize combination of advanced technologies such as, fuel cells, power dense electronics and power dense electric machines and superconducting technologies. How much or which of these concepts will be adopted by industry is unclear, however another step function in electrifying aircraft propulsion is now on the horizon.
Future air vehicles will increasingly incorporate electrical powertrains that require very tight system level integration of power, propulsion, thermal, fault protection, and airframe technologies. This paper provides an overview of a new category of thermal energy conversion technology that can be used to enable a fully solid-state integrated thermal and fault management electric aircraft protection system, while synergistically managing and recycling both the low-grade waste heat from electrical components and the high-grade waste heat from engine components. This is achieved with exergy amplification of the powertrain waste-heat, a new class of fast flight-weight breakers, new class of long variable conductance heat pipe with multiple switchable condensers, new class of turbofan integrated heat exchangers and a gradient-based powertrain system optimizer.
The formulation of a philosophy for devising a reliable, efficient, lightweight, and cost effective electrical power system for advanced, large transport aircraft in the 1980 to 1985 time period is discussed. The determination and recommendation for improvements in subsystems and components are also considered. All aspects of the aircraft electrical power system including generation, conversion, distribution, and utilization equipment were considered. Significant research and technology problem areas associated with the development of future power systems are identified. The design categories involved are: (1) safety-reliability, (2) power type, voltage, frequency, quality, and efficiency, (3) power control, and (4) selection of utilization equipment.
Li-Air batteries are a unique fit for electric aircraft due to their high theoretical energy densities and their potential to leverage on-board oxygen systems. The electrolyte and cathode are the limiting factors for advancing this technology. We are investigating novel "electrolyte and cathode engineering" concepts to enable Li-Air batteries with high practical energy densities, rechargeability and safety. New stable electrolytes and cathodes are being designed and fabricated for Li-Air batteries. An array of various electrolytes were screened and analyzed using NMR and DEMS analysis techniques to understand the fundamental decomposition mechanisms at the cathode surface and within the porous polymer separator. (NMR) spectroscopy has yielded mechanistic insight into decomposition pathway, which is vital to the development of future stable electrolyte candidates. Thus far, five new electrolytes have been screened with 2 showing promising results.
Measurements and analysis of lightning-induced voltages in aircraft electrical circuits
Li-Air batteries are a unique fit for electric aircraft due to their high theoretical energy densities and their potential to leverage on-board oxygen systems. We will investigate novel "electrolyte engineering" concepts integrating computation, material fabrication and cell/pack design to obtain Li-Air batteries with high energy densities, rechargeability and safety.
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.
Battery pack gravimetric energy density is one of the most important, yet often miss- estimated design parameters for sizing all-electric aircraft. Proper accounting for thermal, structural, and operational safety margins are frequently lost when extrapolating performance from the cell level to the aircraft level. This paper summarizes the relevant engineering and certification details needed to better account for the penalties associated when assembling battery packs. The relationship between the cell and pack energy density is not linear, as is often assumed. Furthermore, the relationship varies depending on pack requirements, cell chemistry, and architecture. Parametric, high-fidelity models are used to determine optimal battery pack sizes over a range of conditions to better quantify technology scaling effects.
Conjugate heat transfer (CHT) analysis and optimization is a powerful method for improving thermal management, as it simultaneously resolves the temperature distribution in both fluid and solid domains. This paper presents a modular, discrete adjoint-based CHT optimization capability integrated within the OpenMDAO/MPhys framework. A unique feature of the proposed framework is its flexibility to extend to multidisciplinary optimization, including aero-structural-thermal applications. The fluid domain is modeled using a finite-volume Computational Fluid Dynamics (CFD) solver, and the solid domain with a conduction heat transfer solver. A mixed Neumann-Dirichlet boundary condition is developed to enable full submersion of the solid geometry within the fluid domain, while ensuring consistent temperature and heat flux coupling at the CHT interface. Gradient-based optimization is performed; the gradients are efficiently computed using the discrete adjoint solvers implemented in DAFoam. To demonstrate the method, this paper considers two cases related to electric aircraft thermal management: a U-bend heat exchanger and an actively cooled battery pack. The U-bend case aims to minimize pressure loss while maximizing heat flux by changing the pipe geometry. The optimized design reduces pressure loss by 52.7% and increases total heat flux by 2.3%. In the battery pack case, a 3-by-3 cell configuration is cooled by ambient airflow, with constant heat generation prescribed in the cells. The battery casing shape serves as the design variable, and the objective function is a weighted sum of pressure loss and pack weight, subject to a maximum temperature constraint. The optimized design achieves a 44.6% reduction in pressure loss and a 1.5% reduction in weight, while satisfying the thermal constraint. To ensure the reliability of the optimized designs, this study validates coarse-mesh, steady-state predictions against fine-mesh unsteady simulations, demonstrating consistency within acceptable errors. This work demonstrates the potential of the developed framework to enable rapid, high-fidelity design of thermal management systems for electric aircraft.
Battery pack gravimetric energy density is one of the most important, yet often miss-estimated design parameters for sizing all-electric aircraft. Proper accounting for thermal, structural, and operational safety margins are frequently lost when extrapolating performance from the cell level to the aircraft level. This paper summarizes the relevant engineering and certification details needed to better account for the penalties associated when assembling battery packs. The relationship between the cell and pack energy density is not linear, as is often assumed. Furthermore, the relationship varies depending on pack requirements, cell chemistry, and architecture. Parametric, high-fidelity models are used to determine optimal battery pack sizes over a range of conditions to better quantify technology scaling effects.
It is by no means a simple task to retrieve storm electric fields from an aircraft instrumented with electric field mill sensors. The presence of the aircraft distorts the ambient field in a complicated way. Before retrievals of the storm field can be made, the field mill measurement system must be "calibrated". In other words, a relationship between impressed (i.e., ambient) electric field and mill output must be established. If this relationship can be determined, it is mathematically inverted so that ambient field can be inferred from the mill outputs. Previous studies have primarily focused on linear theories where the relationship between ambient field and mill output is described by a "calibration matrix" M. Each element of the matrix describes how a particular component of the ambient field is enhanced by the aircraft. For example the product M(sub ix), E(sub x), is the contribution of the E(sub x) field to the i(th) mill output. Similarly, net aircraft charge (described by a "charge field component" E(sub q)) contributes an amount M(sub iq)E(sub q) to the output of the i(th) sensor. The central difficulty in obtaining M stems from the fact that the impressed field (E(sub x), E(sub y), E(sub z), E(sub q) is not known but is instead estimated. Typically, the aircraft is flown through a series of roll and pitch maneuvers in fair weather, and the values of the fair weather field and aircraft charge are estimated at each point along the aircraft trajectory. These initial estimates are often highly inadequate, but several investigators have improved the estimates by implementing various (ad hoc) iterative methods. Unfortunately, none of the iterative methods guarantee absolute convergence to correct values (i.e., absolute convergence to correct values has not been rigorously proven). In this work, the mathematical problem is solved directly by analytic means. For m mills installed on an arbitrary aircraft, it is shown that it is possible to solve for a single 2m-vector that provides all other needed variables (i.e., the unknown fair weather field, the unknown aircraft charge, and the unknown matrix M). Numerical tests of the solution, effects of measurement errors, and studies of solution non-uniqueness are ongoing as of this writing.
Engineering and materials concepts for improved aircraft electrical power systems