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

Cutting-edge research in aeronautics is needed to overcome technology barriers and challenges in developing net-zero carbon emissions from aviation by 2050, one of the environmental goals articulated in the White House’s U.S. Aviation Climate Action Plan, and aggressive innovations will be required to reach this goal through development of hybrid-electric machines for aircraft propulsion used for direct-drive propulsion of fans or propellers or as generators, turboprops, or turbofans. High power density propulsion motors are a driving factor for aircraft electrification especially for the larger single and double aisle passenger aircraft. In order to achieve the goal of > 25 kW/kg, it is important to have both stator and rotor high performance and probably both cryogenic. NASA has been advocating the use of all-superconducting rotating machines for electric propulsion. The problem is high AC in the stator. With lower AC losses, High Purity Aluminum (HPAL) Composites configured as multifilamentary wire and cables can out-perform superconductors above 100 Hz for some rotating machine targets. We propose in this project to develop and demonstrate stator coils using multifilamentary, low AC loss, HPAL strands for 20-25 K operation. The use of HPAL low AC loss stands will facilitate aircraft applications in the 1 to 20 MW range enabling high power density motors and generators in the 35-45 kW/kg range, with efficiencies in the range of 99%. During a Phase II effort we will fabricate and characterize HPAL stator coils in an existing 100 kW motor test bed. liquid hydrogen makes an obvious candidate for a thermal sink in the aircraft; the demonstration stator coils will be cooled using liquid and gaseous helium. After the Phase II effort, the technology demonstrated will create both a technical and business pathway for introduction of motors which include our HPAL composite cryogenic conductor 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 those managed by NASA such as the Advanced Air Transport Technology (AATT) Project. Besides electric passenger aircraft, NASA can benefit from many applications where light weight power components are required such as smaller land-based generators, invertor type transformers, 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 a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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.