Lightweight Recuperator for Electrified Aircraft Propulsion

Electrified Aircraft Propulsion (EAP) is a growing NASA technology effort that could enable new configurations of aircraft. With the potential to transform the transportation and services markets, vehicle classes of interest include single-aisle, thin/short haul, and urban air mobility. These vehicle concepts rely on hybrid electric systems to provide propulsive power through the use of a turbo-generator combined with electrical energy storage. For turbo-generators/range-extenders utilized in regional EAP concepts, small lightweight turboshaft engines are an excellent choice due to their maturity and availability. However, at small power scales, gas turbines are less efficient. This can be addressed using a recuperator to inject waste heat from the turbine back into the thermodynamic cycle upstream of the combustor.Micro Cooling Concepts (MC2) has developed technologies for fabricating extremely compact metallic heat exchangers with high heat transfer while reducing size and weight by 2-3X, using the printed circuit heat exchanger (PCHX) approach.Using additive manufacturing to create heat exchangers with finer scale and higher aspect ratio features can magnify the advantages of MC2s existing technology, resulting in recuperators with minimal weight, volume, and pressure losses.Analysis shows that the 3D-printed hybrid laminate recuperators provide reductions in volumes and weight of 4.4X and 7.7X, respectively, compared to conventional recuperators.These weight reductions translate directly into shorter fuel payback times and opportunities to increase payload or range. The program will consist of recuperator design studies, fabrication studies, fabrication and testing of sub-scale test articles, and full-scale prototype fabrication and testing at engine relevant conditions. This effort supports the NASA goal ofreducing the mass and increasing the efficiency of heat acquisition and rejection componentsand advancing technologies for more electric aircraft. NASA's Electrified Aircraft Propulsion (EAP) effort enables new aircraft configurations EAP concepts for single aisle, thin/short haul, and urban air mobility have potential to transform transportation and services markets Some EAP concepts rely on turboelectric propulsion with lightweight turboshaft engines (can lose efficiency at smaller power scales) Integrate recuperator to inject waste heat from turbine into thermodynamic cycle upstream of combustor (Con: adds weight) Micro Cooling Concepts (MC2) previously developed technology for fabricating compact high performance printed circuit heat exchangers (PCHX) MC2 proposes additional improvements through additive manufacturing (AM) to create higher aspect ratio features on recuperator hot side (increase fin effectiveness) Ability to incorporate bypass features enables full power operation without weight/size penalties Comparison with conventional recuperator shows ** 7.7X weight reduction ** Technical Objectives Primary Objective: Develop lightweight compact recuperator using AM Supports NASA goal of reducing mass and increasing efficiency of heat acquisition and rejection components (per 2020 NASA Technology Taxonomy, TX14.2.1 & TX14.2.3) Design recuperator to maximize performance metric (specific conductance - kW/kg/K) Build full-scale prototype recuperator and test at engine-relevant conditions Work Plan Recuperator Design Studies (Thermal/Fluid/Structural/System Performance) Fabrication Trade Studies (Full-Scale) Sub-Scale HX Core Section Fabrication & Testing Full-Scale Prototype Fabrication & Testing (at Engine-Relevant Conditions) Deliverables Recuperator design Sub-scale & full-scale test results Final report

Technology applicable to any NASA program where heat exchangers are required and weight has a significant impact on system performance. Examples include:   Advanced Air Transportation Technology (AATT) Electric Powertrain Flight Demonstration (EPFD) Revolutionary Vertical Lift Technology (RVLT) Advanced Air Mobility (AAM) Convergent Aeronautics Solutions (CAS) Ultra-Efficient Commercial Vehicles Transition to Low-Carbon Propulsion Lightweight compact heat exchangers have uses across wide range of applications. Impact cannot be overstated as applicability to military and commercial sectors is vast:   Energy / Transportation / Space  

This is early/mid-stage (TRL 6) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.