Practical, High-Performance Recuperators for UAS Turbogenerators

Power and propulsion systems for small unmanned aerial systems (UASs) face increasing demands for high efficiency, high power density, and reliability. Small gas turbines offer high power density and excellent reliability, but are less efficient than internal combustion engines. We propose to develop advanced heat exchanger technology that can be used to produce recuperators that will increase the efficiency of small gas turbines. Creare’s advanced manufacturing technology will enable production of compact, lightweight, durable recuperators from established high-temperature alloys at low cost. Our approach also allows the recuperators to be produced in a wide variety of shapes that will enable close integration with the engine and reduce the overall size of the system. In Phase I, we will prove the feasibility of our approach through engine and recuperator performance analysis, proof-of-concept demonstrations, and conceptual design of a recuperated turbogenerator. In Phase II, we will build a prototype recuperator and demonstrate its operation with a small gas turbine engine.