Growing concerns about the environmental impact of aviation have (re)sparked interest in hydrogen aircraft as a greener alternative. However, using hydrogen as fuel introduces technological challenges, particularly with regard to on-board storage. Integral tanks, which are part of the aircraft's main structure, seem promising but existing designs show limitations in their integration with the airframe and insulation capabilities. To address these issues, this study proposes a new integral tank concept featuring a double wall architecture with vacuum insulation and outward facing structural reinforcements connecting to the fuselage skin. A parametric sizing method based on finite element analysis is developed to assess the mass of a tank employing this concept and its sensitivities to design choices. Preliminary results point to fuel containment efficiencies consistent with previous designs, with buckling stability identified as the critical design criterion. These findings provide the basis for further research and could be complemented by integrating the developed framework into a complete aircraft design tool.@en

Hybrid-electric powertrains have shown the potential to reduce aviation climate impact. Since battery capacity is sized for a particular design mission, the emission reduction could be significant when operated at a payload-range combination below the design mission. However, this relation is sensitive to the design point, in particular the design power split ratio and design range. Furthermore, hybrid-electric powertrains would require airlines to adjust their operations. In this study, the interdependencies between hybrid-electric aircraft designs, their off-design performance, and the network's performance are evaluated. The effect of modifying the design range and the design power split ratio on the aircraft's off-design performance and network performance is evaluated. Several designs are constructed and several operational scenarios are generated. The Air Nostrum network is used as a case study. It is found that when the off-design performance of the hybrid-electric aircraft is considered in the fleet assignment and scheduling of an airline, CO2 savings equal to 15% can be attained while incurring a minimal loss in profit of 1.35%. This research highlights how modifying the design range of hybrid-electric aircraft has a larger impact on the applicability of the former in regional airline networks than the modification of the design power split ratio.@en

Battery-electric aviation is commonly believed to be limited to small aircraft and is therefore expected have a negligible impact on the decarbonization of the aviation sector. In this paper we argue that, with the correct choice of design parameters and top-level aircraft requirements, the addressable market is actually substantial. To demonstrate this, the Class-II sizing of a battery-electric 90-seater is performed, and the environmental impact is assessed in terms of well-to-wake CO2-equivalent emissions per passenger-kilometer. The resulting 76-ton aircraft achieves a battery-powered useful range of 800 km for a pack-level energy density of 360 Wh/kg. For this range, it has an energy consumption of 167 Wh per passenger-kilometer and an environmental impact well below that of kerosene, eSAF, or hydrogen-based aircraft alternatives and comparable to land-based modes of transport. These results indicate that, to successfully reduce the climate impact of the aviation sector, battery-electric aircraft should not be designed as a niche product operating from small airfields but as commercial transport aircraft competing with fuel-based regional and narrowbody aircraft.@en

Propeller-wing configurations are expected to return to the aviation industry due to their high propulsive efficiency and applicability in urban and regional air mobility. A knowledge gap exists around wing-propeller optimization because of the complexity of the propeller-wing system and the absence of a computationally efficient way to assess the coupled system. This paper addresses this gap by providing and validating a computationally efficient, mid-fidelity framework. The paper presents optimization results and recommendations for future iterations of the framework. The TU Delft PROWIM propeller is optimized with the framework, comparing sequential isolated optimization, trim optimization, and fully coupled optimization. The studies gives a conservative estimate of the efficiency gains that can be achieved by using coupled optimization, as compared to isolated optimization. Lastly, recommendations are given for future studies, such as including a battery weight model and including swirl velocities. It is expected that such model additions will affect the optimization results, and further emphasize the importance of coupled aerostructural optimization.@en

HYLENA will investigate, develop and optimize an innovative, highly efficient integrated hydrogen powered, electrical aircraft propulsion concept for short and medium range. It will achieve significant climate impact reduction by being completely carbon neutral with radical increase of overall efficiency. The full synergistic use of: a) an electrical motor (as the main driver for propulsion), b) a contoured hydrogen fueled SOFC stacks (geometrically optimized for nacelle integration), c) a gas turbine (to thermodynamically integrate the SOFC), will act as an enabler for hydrogen aviation and will allow for efficient and compact engine concepts. This disruptive propulsion system will be called HYLENA concept. HYLENA aims to evaluate and demonstrate the feasibility of a “game changing” engine type which integrates Solid Oxide Fuel Cells (SOFC) into a turbomachine, in order to utilize the heat generated by the fuel cells on top of its electrical energy. The combination of e-motor, turbomachine and contoured SOFCs fueled with H2 will deliver high overall efficiency and performance versus state-of-the-art turbofan engines. Indeed, HYLENA Figures of Merit consist of minimizing CO2 emission; negligible NOX and an unmatched overall efficiency versus state-of-the-art turbofans which corresponds to an outstanding performance increase. It will also enable to extend the flight range for the same fuel tank size. The HYLENA project will deliver: 1. On SOFC cell level: Experimental investigations on SOFC cell technologies and identification of the most promising one(s) for aeronautical applications; 2. On SOFC stack level: Studies and tests to determine the most compact/light/manufacturable way of stack integration; 3. On thermodynamic level: Cycles simulations of the proposed novel HYLENA concept architecture and down selection of the most performing one; 4. On engine design level: Exploration, through resilient calculation and simulation, of the best engine design, sizing and overall components integration; 5. On overall engine efficiency level: Demonstration that HYLENA concept can reach very high efficiency levels with limited weight and complexity; 6. On demonstration level: A decision dossier for a potential ground test demonstrator to prove that the HYLENA concept works in practice during a second phase in the continuity of this project.

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Results from the APPU project, which investigated the concept of an "Auxiliary Power and Propulsion Unit" (APPU) are presented. The APPU is a hydrogen-driven boundary-layer-ingesting engine at the tail end of a passenger aircraft which replaces the conventional APU and contributes about 15% of total thrust at top of climb. The aim of the configuration is to allow the introduction of hydrogen and BLI technology by upgrading existing aircraft designs. The concept aims to benefit from the advantages of these new technologies as much possible, without requiring the same level of reliability as for conventional propulsion, during times when hydrogen infrastructure is not universally available. The investigation concerns hydrogen tank mass, engine efficiency, operational, aerodynamic and reliability aspects, and finds block CO2 emissions can be reduced by a larger amount than the thrust rating of the auxiliary hydrogen engine may suggest. One reason for this is that the additional engine permits smaller and more efficient designs for the main engines. A still larger benefit is found to arise out of the assumption that the APPU engine and associated H2 fuel systems is less reliable than the conventional underwing engines. This assumption permits different strategies to maximize the utilization of hydrogen over kerosene. CO2 emissions for the design mission are found to be reduced by 23.1% over the A321neo, and by 15.5% over an A321neo fitted with updated turbofan engines.

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Within the work package radical new aircraft configuration of Cleansky2 Large Passenger Aircraft, a benefit of more than 20% in fuel consumption and CO2 emission (one of CS2 top level objectives) could be achieved by using various Distributed (hybrid) Electric Propulsion DEP architectures on different more or less radical aircraft configurations. It has therefore been identified as a disruptive technology which shall be de-risked in terms of achievable performance during wind tunnel tests and in terms of handling qualities during flight tests. The electric architecture with typical magnitudes shall also be studied in more detail. As already presented during AIAA SciTech Forum and Exhibition 2023, the D08 Distributed Electric Propulsion DEP version of the D03 Scaled Flight Demonstrator has been designed, manufactured and ground tested from 2020 to May 2023. An incident during the last ground test in May 2023 caused the total loss of this demonstrator. After its analysis, it was decided to robustify the electric architecture by improving the batteries, the wiring, the protections and the monitoring. These changes in the electric architectures lead to structural changes like the shift of the emergency parachute and bigger access hatches. The remanufacturing of the DEP-SFD2 has started in September 2023 for an exhaustive integration test campaign and taxi tests in January and February 2024. At the moment, the qualification flight tests will take place in April 2024 and the mission flight tests in May 2024.@en

Thus far, battery-electric propulsion has not been considered a promising pathway to climate-neutral aviation. Given current and expected battery technology, in most literature battery electric aircraft are only considered feasible for short ranges (< 400 km) and small payloads (< 19 pax). As a result, battery-electric aircraft development focuses on new aviation segments such as regional and urban air mobility. However, little effort has been made to develop battery-electric aircraft that can replace existing larger aircraft. This paper re-examines the assumptions that lead to the conclusion of limited applicability of battery-electric aircraft. Starting from the range equation, this paper assesses the drivers of two key parameters: the ratio between energy mass and maximum take-off mass, and the maximum lift-to-drag ratio. This assessment, based on Class-I mass and aerodynamic-efficiency estimates, shows that there is a design space where these two parameters can reach significantly higher values than often assumed in the open literature. Based on this finding, several parametric aircraft designs are evaluated, relying on Class-II mass and aerodynamics methods. These parametric studies validate the conclusion from the Class-I assessment. This implies that battery-electric passenger aircraft can play a larger role in climate-neutral aviation than was previously envisioned.

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HYLENA will investigate, develop and optimize an innovative, highly efficient integrated hydrogen powered, electrical aircraft propulsion concept for short and medium range. It will achieve significant climate impact reduction by being completely carbon neutral with radical increase of overall efficiency. The full synergistic use of: a) an electrical motor (as the main driver for propulsion), b) a contoured hydrogen fueled SOFC stacks (geometrically optimized for nacelle integration), c) a gas turbine (to thermodynamically integrate the SOFC), will act as an enabler for hydrogen aviation and will allow for efficient and compact engine concepts. This disruptive propulsion system will be called HYLENA concept. HYLENA aims to evaluate and demonstrate the feasibility of a “game changing” engine type which integrates Solid Oxide Fuel Cells (SOFC) into a turbomachine, in order to utilize the heat generated by the fuel cells on top of its electrical energy. The combination of e-motor, turbomachine and contoured SOFCs fueled with H2 will deliver high overall efficiency and performance versus state-of-the-art turbofan engines. Indeed, HYLENA Figures of Merit consist of minimizing CO2 emission; negligible NOX and an unmatched overall efficiency versus state-of-the-art turbofans which corresponds to an outstanding performance increase. It will also enable to extend the flight range for the same fuel tank size. The HYLENA project will deliver: 1. On SOFC cell level: Experimental investigations on SOFC cell technologies and identification of the most promising one(s) for aeronautical applications; 2. On SOFC stack level: Studies and tests to determine the most compact/light/manufacturable way of stack integration; 3. On thermodynamic level: Cycles simulations of the proposed novel HYLENA concept architecture and down selection of the most performing one; 4. On engine design level: Exploration, through resilient calculation and simulation, of the best engine design, sizing and overall components integration; 5. On overall engine efficiency level: Demonstration that HYLENA concept can reach very high efficiency levels with limited weight and complexity; 6. On demonstration level: A decision dossier for a potential ground test demonstrator to prove that the HYLENA concept works in practice during a second phase in the continuity of this project.

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The potential of Distributed Electric Propulsion (DEP) for future aircraft has been evaluated with Scaled Flight Testing (SFT). Scaled flight testing can contribute to a reduction of risk and cost in the development of a radically new aircraft. The flight dynamics and control of the aircraft have specifically been addressed. The validity of results of scaled flight testing for predicting the full-scale aircraft properties was addressed in a first campaign. A 1:8.5 scaled version of a typical large passenger aircraft was built, tested in the wind tunnel and was subsequently flight tested. During the flight tests an accurate flight test instrumentation system measured the scaled aircraft flight parameters, such as motion, control surface deflections and air data. Results of the scaled flight testing have been compared with full-scale test results which validates the scaled flight testing methodology. In a second campaign the methodology is applied to investigate and demonstrate the benefits of distributed electric propulsion. Aircraft with the same external shape have been used in the two test campaigns, modifying only the propulsion: the twin turbo-jet propulsion of the first campaign was replaced by propulsion with six propellers in the second campaign. This paper presents the highlights and key results of the development, manufacturing, wind tunnel tests, ground tests, taxi tests and flight tests of both campaigns.

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Electrification of aviation is regarded as one of the means to make aircraft operations less polluting and to have lower climate impact. Yet, air transportation's environmental impact depends on power train technologies and novel designs and aircraft operations within airline networks. Fully- or hybrid-electric aircraft may enter existing air transport networks through fleet replacement yet require airlines to adapt in order to operate electrified aircraft strategically. This research studies how airlines can strategically adjust their network and fleet composition when considering electrified aircraft. The novelty of this approach is to provide a direct feedback coupling between fleet planning, conceptual hybrid-electric aircraft design and climate impact minimization. Therefore, a strategic airline planning model, consisting of fleet and network analysis, is coupled to a hybrid-electric aircraft design model. A case study on the sensitivity of a regional airline network is presented to demonstrate the framework and assess the impact of trying to design aircraft and fleets with minimal climate footprint. A decrease in emissions with respect to a kerosene fleet of 11% can be achieved when a hybrid-electric fleet is designed particularly for the specified network, at the penalty of a profit decrease of 13%. Limiting fleet diversity to three types results in only 7% emissions decrease. Increasing the battery-specific energy shows an expected beneficial effect on emissions.@en

The objective of the EU-funded research project CHYLA (Credible HYbrid eLectric Aircraft) was to identify opportunities or limitations/challenges for the applications of key radical hybrid-electric technologies and areas suitable for scaling them over different aircraft classes. This was done using a ombination of conceptual aircraft design supported by sensitivity studies, credibility-based MDO and assessment of a regional operative scenario. This article summarizes the key findings from the project and presents the landscape of technology application areas. Notably, the regional and commuter classes present the largest design space with significant fuel-saving potential depending on the mission.@en

The impact of the ICAO code C gate span limit is assessed on the sizing of a serial Hybrid Electric Aircraft (HEA) of increasing Degree of Hybridization (DoH). For a set of Top Level Aircraft Requirements (TLARs) similar to the ATR-42, it is shown that the increase in MTOM due to the presence of the battery is such that only a maximum DoH under 30% can be achieved before the wing span of the serial HEA reaches the 36 meters gate size. The same aircraft is fitted with Leading Edge Distributed Propulsion (LEDP) to increase the wing loading and relieve the span constraint, though this introduces limitations regarding the available wing volume. It is shown that a combination of high wing loading and of low volumetric energy density for batteries compared to jet fuel can lead to the available wing volume being too small for the required volume of the energy carriers. Finally a value in wing loading is found which simultaneously meets the span and wing-volume constraints. The higher DoH enabled by LEDP leads results in a 33% reduction in fuel burn compared to the fuel-based reference aircraft, while the overall energy consumption is increased by 6%.@en

Decades of improvements of engine efficiency on internal engine components through better materials, design methods and novel fabrication techniques have resulted in fuel consumption reductions. Another major factor for improving engine fuel consumption has been the increase of bypass ratio. However, this has a significant impact on engine dimensions and weight, and, consequently, the installation of the engine on the airframe. Evaluation of engine installation penalties is not a new topic; literature provides various studies on aerodynamic effects. These primarily studied the effects of drag increase and the impact on drag of engine location and nacelle shape. This article investigates the performance impact of installation penalties from an increase in bypass ratio on narrow body aircraft, specifically the fuel consumption, weight and stability. Additionally, an analysis is made comparing aircraft retrofit and redesign for increased bypass ratio engines. It can be concluded from retrofit analyses that engine size is more significant than its location. Changes in aerodynamic center, CLα , and CMAC cause stability/controllability criteria to shift to the left. Heavier engines at the same spanwise location cause a more forward CG location, which may become limiting. With the engine increasing in size (thus increasing the drag and increasing the weight), the overall increase in fuel burn is 5.9%. However, the decrease in fuel burn due when the SFC and engine effects are considered together, the fuel burn drops by 50%. The reduction in fuel burn thereby negating the increase in engine weight, drag, and integration issues. From BPR 10 onwards, the decreasing trend in tail size stagnates and actually reverses, indicating that larger tail sizes might be required for even larger BPR engines.@en

Differential thrust can be used for directional control on distributed electric propulsion aircraft. This paper presents an assessment of flight dynamics and control under engine inoperative conditions at minimum control speed for a typical distributed propulsion aircraft employing differential thrust. A methodology consisting of an aerodynamic data acquisition module and a non-linear six-degrees-of-freedom flight dynamics model is proposed. Directional control is achieved using a controller to generate a yaw command, which is distributed to the propulsors through a thrust mapping approach. A modified version of the NASA X-57 aircraft is selected for case studies, where the engine inoperative condition is considered to impact the three leftmost propulsors during climb at minimum control speed. The objective also includes the assessment of the impact of the aero-propulsive coupling for such an aircraft during a failure case. Results show that during the recovery manoeuvre, the aircraft experiences a 78% reduction in total thrust and 30% reduction in total lift caused by the aggressive yaw control effort required to control the heading of the aircraft. Consequently, the powered-stall speed is increased, and the aircraft temporarily loses altitude during the recovery manoeuvre. Differential thrust provides sufficient yaw authority during the engine inoperative condition, and is, therefore, seen to potentially replace the functionality of the rudder for the climb condition that was studied. Additionally, reduction of the vertical tail area was explored and seen to be possible if the response time of the system is low enough. For the studied configuration, this required a response within 400 ms for reduced vertical tail areas.

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The concept of an "Auxiliary Power and Propulsion Unit" (APPU) is introduced, which consists of a Boundarylayer ingesting (BLI) propulsor with an engine mounted at the rear of an passenger aircraft fuselage, replacing the Auxiliary Power Unit (APU) and contributing around 10% of total cruise thrust, as well as auxiliary power. This APPU unit is using hydrogen provided by an additional tank installed in the tailcone of the aircraft. The concept is aimed at lowering the threshold to installing both hydrogen-driven propulsion and BLI propulsors on aircraft in the short term, while minimizing resulting operational risk. The concept has been investigated using a preliminary aircraft synthesis tool and further component-level mass estimates. Operational aspects,
sensitivities and limits to the design have been investigated. Estimates of mission fuel burn find that CO2 emissions emissions reduce roughly proportionally to the APPU thrust share, with additional savings due to improved overall efficiency. Further improvements are deemed feasible and are the topic of ongoing research.@en

Various research initiatives in hybrid-electric/sustainable aviation typically address only a single vehicle or single vehicle class. However, novel propulsion and energy solutions can be expected to be differently applied in different vehicle classes. The objective of the EU funded research project CHYLA (Credible HYbrid eLectric Aircraft) is to identify areas suitable for scaling, as well as limitations or challenges for development for the applications of key radical technologies on different classes of aircraft. This article provides an overview of the design approach followed for the CHYLA project, as well as initial radical designs and comparison to the CHYLA baselines. These provide the starting point for both the sensitivity study which will be presented in a later scalability assessment and economical assessments in the CHYLA project. A variety of regional, short medium range and large aircraft has been designed, all according to the same TLAR yet without detailed tuning of important power control variables. Results are distinguishable between concepts and provide sufficient detail to capture the necessary effects. The reduction of fuel consumption will require detailed assessment and fine tuning, though reductions may be achievable for regional and possibly SMR aircraft. @en

The current focus in the aviation industry for more sustainable designs, could mean the revive of propeller propulsion, due to their relative high propulsion efficiency compared to jets. In addition, wingtip-mounted propellers installed in tractor configuration can be used as tip-vortex attenuating devices, reducing the wing induced drag. So far, studies on wingtip-mounted propellers mainly concentrated on the aerodynamic interaction effects, disregarding the integration with the airframe and wing-structural mass. This paper presents a method to integrate into an aircraft sizing process the aerodynamic, aero-propulsive, and aero-structural effects of tip-mounted propellers, in the context of a typical turboprop featuring hybrid-electric propulsion. Subsequently, a number of case studies are performed to investigate the sensitivity to modifications of the propulsion system on wing and aircraft level. Results show that the performance benefit gained by the application of a wingtip-mounted propeller is easily overruled by the weight penalty that it introduces, an almost linear relationship between shaft power ratio and MTOM was observed. For variations of propeller diameter, it is seen possible to attain equal performance in terms of energy efficiency with a mass penalty. For phi=0.1, the reference performance is obtained for a tip-mounted propeller occupied span fraction of 0.175 with an increase in MTOM of 2.8%. For phi=0.2, this is obtained at a larger tip-mounted propeller (occupied span fraction = 0.275) and an increase in MTOM of 5% compared to the reference design. @en

This study aims at providing a landscape of opportunities and limitations for hybrid-electric aircraft (HEA) and hydrogen-powered aircraft by investigating several technological combinations applied to three aircraft classes: Regional (REG), Short-Medium Range (SMR) and Large Passenger Aircraft (LPA). The preliminary sizing of HEA using different hybrid-electric powertrain architectures, combined with various distributed propulsion layouts is conducted. The resulting HEA are then compared to a conventional design, on the basis of several performance metrics, for variations in harmonic range and passenger capacity. Throughout the design space considered, it is found that opportunities for radical aircraft design are scarce and offer limited prospective.

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Zero-carbon-dioxide-emitting hydrogen-powered aircraft have, in recent decades, come back on the stage as promising protagonists in the fight against global warming. The main cause for the reduced performance of liquid hydrogen aircraft lays in the fuel storage, which demands the use of voluminous and heavy tanks. Literature on the topic shows that the optimal fuel storage solution depends on the aircraft range category, but most studies disagree on which solution is optimal for each category. The objective of this research was to identify and compare possible solutions to the integration of the hydrogen fuel containment system on regional, short/medium- and large passenger aircraft, and to understand why and how the optimal tank integration strategy depends on the aircraft category. This objective was pursued by creating a design and analysis framework for CS-25 aircraft capable of appreciating the effects that different combinations of tank structure, fuselage diameter, tank layout, shape, venting pressure and pressure control generate at aircraft level. Despite that no large differences among categories were found, the following main observations were made: (1) using an integral tank structure was found to be increasingly more beneficial with increasing aircraft range/size. (2) The use of a forward tank in combination with the aft one appeared to be always beneficial in terms of energy consumption. (3) The increase in fuselage diameter is detrimental, especially when an extra aisle is not required and a double-deck cabin is not feasible. (4) Direct venting has, when done efficiently, a small positive effect. (5) The optimal venting pressure varies with the aircraft configuration, performance, and mission. The impact on performance from sizing the tank for missions longer than the harmonic one was also quantified.@en