High Power Density Motors/Generators for Single and Double Aisle Passenger Aircraft using Multifilamentary High Purity Aluminum Coils at 20K

This SBIR proposal is submitted in response to Topic A1.09, “Zero Emission Technologies for Aircraft”. For this Phase I and II we propose to develop and demonstrate stator coils using multifilamentary, low AC loss, high purity aluminum (HPAL) strands for 20-30 K operation. These strands can be safely cooled using gaseous or liquid helium in the 20-30K range. Liquid hydrogen can be the fuel in the aircraft by using a heat exchanger and a secondary loop of pressurized liquid helium to cool the motor or generator. The use of HPAL low AC loss stands will enable high power density motors and generators in the 35-45 kW/kg range, with efficiencies in the range of 99%. HPAL low AC loss coils for stators can enable rotating machines at higher frequencies than superconductors, allowing for much higher rpm machines that are light weight. During the Phase I we will fabricate and test multifilamentary low AC loss strands, cables and coils. During a Phase II effort we will fabricate and demonstrate HPAL stator coils and test the stator coils in an existing 100 kW motor test bed. After the Phase II effort, the technology demonstrated will lead to the commercialization of 2 MW class motors and generators for single and double aisle passenger aircraft.

Electric single and double aisle passenger aircraft will benefit greatly from the proposed HPAL stator coils and the resulting motors and generators. This motor synchronizes with the demands of multiple electric aircraft R&D programs, including NASA SUSAN. Other than electric passenger aircraft, NASA can benefit for many applications where light weight power components are required such as smaller land-based generators, invertor, inductors, higher frequency power conditioning equipment, MHD magnets, electric aircraft busbars, electrical cables, and propulsion engines. When liquid hydrogen is available as a fuel, any high speed rotating machines would benefit greatly from this proposed research. This includes aircraft, offshore oil platforms, marine propulsion and mobile and stationary generator systems. In addition, non-NASA invertor transformers would benefit from this proposed research.

This is early/mid-stage (TRL 3) — 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.