Transportation

To make the power density of electric aircraft closer to conventional aircraft, an electric power system (EPS) with high power delivery and low system mass is necessary. As an essential component of aircraft EPS, cables are necessary to transmit power from one node to another. Virginia Tech will develop a high-power density, cost-effective ±5 kV cable for twin-aisle all-electric aircraft.

GE Research will develop a safe, lightweight, and altitude-capable megawatt power cable system with electromagnetic interference shielding capability for large aircraft. The proposed 10 MW cable system is expected to achieve ten times greater power density than conventional technology without degradation by partial discharge and is fire safe and oil resistant.

There are two key engineering challenges in the development of 10 kV, 10 MW electric power distribution cables for double-aisle passenger aircraft. One is providing sufficient electrical insulation at high voltages and the second is transferring heat away from the conductors.

The Zero-carbon Ammonia-Powered Turboelectric (ZAPTurbo) Propulsion System is a very high efficiency and lightweight turboelectric system that uses green ammonia as a fuel and coolant via regenerative cooling. Coke-free heating of this carbon-free ammonia fuel enables a high level of waste-heat recovery that will be used for the endothermic cracking of ammonia prior to its combustion, significantly increasing the cycle efficiency. The proposed propulsion system includes an efficient AC electric powertrain for turboelectric cruise, with battery boost for takeoff and climb flight phases.

Increasing the efficiency of power generation and air transportation can only be achieved by increasing the temperature at which generation/propulsion turbines operate. The emerging Refractory High Entropy Alloys (RHEAs) can enable much higher operating temperatures than the state-of-the-art. Identifying the alloys' chemistry is difficult due to the vastness of the RHEA chemical space.

The University of Maryland will leverage a newly invented, ultrafast high-temperature sintering (UHS) method to perform fast exploration of new environmental-thermal barrier coatings (ETBCs) for 1300°C-capable refractory alloys for harsh turbine environments. UHS enables ultrafast synthesis of high-melting oxide coatings, including multilayers, in less than a minute, enabling rapid evaluation of novel coating compositions.

The drive for higher fuel efficiency and higher core power of gas turbines used in electric power generation and aircraft propulsion requires higher peak operation temperatures in the hottest sections. Current state-of-the-art refractory metal alloys (RMAs), although highly resistant to heat and wear, tend to oxidize in the gas turbine environment.

Raytheon Technologies Research Center (RTRC) aims to design and validate the manufacturability and mechanical properties of a new hot section turbine alloy. To achieve higher efficiency turbine operation, RTRC will use additive manufacturing (AM) to produce test coupons (specimens) and potentially a representative turbine blade using a high entropy alloy (HEA) enhanced with oxide dispersion strengthening (ODS) particles.

Massachusetts Institute of Technology will develop a new additive manufacturing (AM) process, capable of producing refractory composite materials for use in high-temperature, oxidation-resistant turbine blades and other demanding energy-conversion applications. The AM process will incorporate hardware and software to establish uniform, high-quality refractory materials that are traditionally prone to micro-cracking and oxidation during AM, thereby establishing the required mechanical properties and oxidation resistance of a target alloy.

The University of Utah will use physical metallurgy principles and artificial intelligence to identify the chemistry of new niobium (Nb)-based refractory alloys to ensure they have excellent high-temperature properties without being brittle at low temperatures. The artificial intelligence approach will discover promising compositions for the new alloys based on existing knowledge of simple alloys. The computational materials models will be used to predict the proper processing conditions for the material chemistries.