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 by using a recuperator to inject waste heat from the turbine back into the thermodynamic cycle upstream of the combustor.nbsp;Micro Cooling Concepts (MC2) has developed technologies for fabricating extremely compact metallic heat exchangers with high heat transfer while reducing size by 3-5X 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 MC2rsquo;s existing technology, resulting in affordable recuperators with minimal weight, volume, and pressure losses.nbsp;Analysis shows that the PCHX approach gives ~50% weight reduction, while the 3D Printed/Hybrid recuperators provide an additional 20% weight reduction.nbsp;These weight reductions translate directly into shorter fuel payback times and opportunities to increase payload or range.nbsp;The program will begin with requirements definition and design studies to size the heat exchanger and assess flow distribution. 3D printing studies will assess manufacturability of the concept, followed by fabrication and testing of proof pressure test specimens, representative of a full-scale recuperator design. The program will conclude with a design update to prepare for the Phase II effort.