To increase efficiency, reduce weight, and improve performance of next-generation aircraft, it is essential to design integrated systems that comprise multiple functionalities. Modern propulsion systems integrate aircraft engines and air intake diffusers into the airframe to reduce drag. However, such diffusers often introduce undesirable flow features such as flow separation and distortions, thus reducing the efficiency of propulsion systems. Continuum Dynamics, Inc., The Pennsylvania State University, and Reaction Engines, Inc. propose to design a multifunctional heat exchanger device in the form of a guide vane cascade that can simultaneously extract swirl and flow distortions for improved engine performance and dissipate a large amount of aircraft waste heat. This technology will allow for unobtrusive installation and retrofitting into existing engine intake diffusers (e.g., serpentine ducts). Accordingly, the emphasis of Phase I effort will be on performing numerical simulations, multi-objective optimization processes, and preliminary experimental testing in a simplified flow environment at bench level to demonstrate the feasibility and practicality of the proposed heat exchanger technology. Phase II will focus on finalizing the design, fabrication, and ground testing of the proposed device to further evaluate heat exchanger effectiveness, pressure loss, and distortion reduction for a representative inlet geometry under various operating conditions.
Benefit: A successful Phase I/Phase II effort will produce a dual-purpose vane-like device integrated into an existing aircraft inlet that simultaneously serves as a heat exchanger and a flow straightener upstream of the AIP. The proposed technology will directly support a range of fundamental goals for enhancing performance and improving operational safety and reliance of advanced propulsion systems for the Navy and other U.S. Department of Defense agencies. The developments projected here would expand beyond military specific applications and can further benefit the commercial transport aircraft and automotive industries. Follow-on activity would build upon the proposed technology to develop a more efficient regenerative engine cycle where the waste exhaust thermal energy is harvested to preheat the engine intake air flow and thus further reduce fuel consumption, which would directly benefit both commercial and military systems. In addition, significant commercialization opportunities are anticipated from providing services and licensing the engineering design and optimization software package to heat exchanger manufacturers and branches of the government involved in aerospace heat exchanger R&D, fabrication, and testing.
Keywords: Flow Swirl and Distortions, Flow Swirl and Distortions, Guide Vanes, heat exchanger, additive manufacturing., Engine Inlets, Multi-objective optimization
