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 typically 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 coupling with the turbogenerator, reduce the overall size of the system, and simplify integration with the aircraft. In Phase I, we proved the feasibility of our approach through engine and recuperator performance analysis and system optimization, proof-of-concept demonstrations of critical components, and conceptual design of a recuperated turbogenerator. In Phase II, we will build prototype recuperators, measure their performance under prototypical operating conditions, and demonstrate durability over hundreds of operating cycles. We will use these data to compute the reductions in fuel consumption that are possible in a 5 kWe turbogenerator.