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During research and development for NASA’s X-57 Maxwell all-electric aircraft project, the efficiency and power density requirements of its electric propulsion subsystem components were met, but aspects of integrating its powertrain subsystems proved problematic. Electromagnetic interference (EMI) from the cruise motor controller (CMC) was a significant challenge for the project. This problem was exacerbated by the lack of EMI requirements imposed on subsystem powertrain components. This report presents the results of EMI testing of the X-57 high lift motor controller (HLMC) at the NASA Glenn Research Center’s EMI Laboratory. For reference, the conducted emissions are compared to DO–160G and MIL–STD–61G conducted emissions limits. After the EMI test, mitigation of the conducted emissions using lightweight EMI chokes produced at NASA Glenn was evaluated using the Fast Fourier Transform (FFT) capability of an oscilloscope in the hardware development laboratory. This process can contribute to the rapid prototyping of electric powertrain components and EMI filters and improve the likelihood of successful EMI qualification at the component and system levels.

NASA's X-57 all-electric aircraft was a research project aimed at investigating lightweight and efficient electric propulsion components. The general approach was to utilize a distributed electric propulsion (DEP) design. An essential component of this design was the High Lift Motor Controller (HLMC), a motor drive which provided power to the High Lift Motors (HLMs) and High Lift Propellers (HLPs) responsible for providing additional thrust for take-off and landing. This paper presents the detailed design, test results, and outcomes from the development of the HLMC, a 14 kW, 1kg, 98.3% efficient, outer mold line (OML) cooled, silicon carbide (SiC) MOSFET-based inverter and controller.

Electric aircraft require high reliability electric motors to meet the stringent safety standards of the aviation industry. Motor winding insulation lifetime and reliability models for electric aircraft applications are needed to enable design of high reliability and high-performance electric motors for aviation applications. Three primary stresses effect the lifetime of motor winding insulation: thermochemical, mechanical, and electrical. This paper presents preliminary experiments on twisted pairs of magnet wire targeting understanding the thermo-chemical degradation of motor winding insulation through constant temperature thermal aging. Three types of magnet wire twisted pairs where tested: polyimide insulated magnet wire, epoxy coated polyimide insulated magnet wire, and epoxy potted polyimide magnet wire. The degradation of the samples over time at temperature was tracked using partial discharge inception voltage measurements. These initial experiments were used for development of procedures and expertise in partial discharge testing and thermo-chemical aging to inform future testing. The preliminary nature of these experiments should be noted when viewing the results. Lessons learned from the experiments are documented.

Exploration of Venus below its clouds has long been impaired by the planet’s massive CO2 atmosphere, corrosive trace gases, and high opacity. Except for a few narrow spectral windows, the 20 km thick global cloud cover blocks light over the entirety of the ultraviolet through thermal infrared spectrum, impeding orbital studies of the surface and lower portion of the atmosphere. In addition to the cloud opacity, Rayleigh scattering through 80 bars of CO2 in the lower 40 km of the atmosphere results in a Rayleigh scattering depth between 25 and1 in the visible through near infrared portion of the spectrum. That optically thick scattering, combined with the uniform angular distribution of the illumination provided by the highly diffusing clouds overhead greatly reduces even very large surface albedo contrasts (Crisp, pers. Comm.). To date, the surface has only been mapped via synthetic aperture radar by the Magellan mission at scales of 120 to 300 m/pixel. In addition to contributing to the difficulty of performing studies of the surface from orbit, the extreme temperatures and pressures at the surface also create a challenging environment to utilize a lander for exploration. The longest-lived lander on Venus’ surface survived for 2 hours. Hence, limited access to observe the surface and lower atmosphere of Venus arguably puts the surface and lower atmosphere of Venus as one of the least explored regions of the inner Solar System.

NASA’s Hybrid Thermally Efficient Core (HyTEC) project aims to accelerate the development of small-core turbofan engine technologies to enable a fuel burn reduction of 5 to 10 percent for next-generation aircraft, compared to 2020s best-in-class technology. This paper presents a demonstration of methods for evaluating the potential performance impact of small-core engine technologies developed under Phase 1 of the HyTEC project. The approach involves model-based systems analysis, where small-core innovations are integrated into baseline turbofan and aircraft systems models, creating a notional vision system. Performance of the vision system is examined at both the engine and vehicle level. The examined performance metrics include: engine bypass ratio, overall pressure ratio, high pressure compressor exit corrected mass flow, and aircraft fuel burn. The CFM LEAP-1B28 and Boeing 737 MAX 8 are chosen as the baseline state-of-the-art systems. Preliminary results map a design space for the small-core vision system and quantify the distinct effects of technologies on the key metrics.

The aeroelastic stability of a tail cone thruster fan was analyzed for three structural modes and various nodal diameter patterns. Computational fluid dynamics modeling with blade vibrations was used in the analyses performed at design (peak-efficiency) and two near-stall conditions at the design rotational speed. Aerodynamic damping was used to assess flutter since this integrally bladed rotor design will have minimal structural damping. Aerodynamic damping was found to be low at the design condition. For the first mode, aerodynamic damping was seen to decrease towards stall, vanishing for a zero nodal diameter pattern. Further decrease in mass flow led to negative aerodynamic damping (flutter) for the first and second nodal diameters in the near stall condition. The flowfield at this lowest mass flow rate exhibited some additional unsteadiness at higher frequency. The sensitivity of results to time step and amplitudes of vibration was examined and found to be very satisfactory. The largest uncertainty in the results comes from the observed sensitivity of the aerodynamic damping to details of the variation of grid deformations in the blade passage mesh from the blade passage to the boundaries. For the parametric variations analyzed, the calculated aerodynamic damping is lower if the grid deformations near the blade surface are higher. Further work is needed to understand the cause of this sensitivity and find possible solutions to reduce the effects on flutter predictions.