Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Comparative cost and material analysis of conventional vs_ proposed aerospace generator designs (Innovation_ Carpenter Technology, n_d_; Metal powders | Höganäs, n_d_; VAC - Advanced Magnetic Solutions | VAC, n_d_)_
| Component | Material (Trad./Prop.) | Weight (kg) (Conv./Prop.) | Cost of conventional aerospace generator (USD) | Cost of proposed design aerospace generator (USD) |
|---|---|---|---|---|
| Stator lamination (Back) | Hiperco 50/Finemet FT3M | 2.469/2.222 | 1,728.30 | 666.60 |
| Stator lamination (tooth) | Hiperco 50/Finemet FT3M | 2.293/2.064 | 1,605.10 | 619.20 |
| Rotor lamination (total) | Hiperco 50/SMC HB1 | 0.6339/0.5862 | 443.73 | 70.34 |
| Armature winding (active) | Copper/Litz wire | 2.163/1.114 | 35.77 | 33.42 |
| Armature end winding (total) | Copper/Litz wire | 2.121/0.546 | 35.10 | 16.38 |
| Magnet | Recoma 28 | 0.6147 | 737.64 | 737.64 |
| Rotor banding | Inconel 718 | 0.1397 | 11.18 | 11.18 |
| Shaft (total) | Steel (general) | 2.425 | 4.85 | 4.85 |
| Total estimated cost | $4,601.67 | $2,159.61 | ||
| Cost reduction | 53.1% |
Material properties of the proposed and conventional aerospace generator designs (Tian et al_, 2025; Wang and Wang, 2011)_
| Parameters | Proposed design material | Conventional design material | Unit | |
|---|---|---|---|---|
| Stator core | Rotor core | |||
| Lamination thickness | 0.018 | 0.05 mm | 0.15 | mm |
| Relative permeability (µr) | 80,000–100,000 | 200–500 | 18,000 | |
| Poisson’s ratio | 0.3 | 0.32 | 0.3 | |
| Thermal conductivity | 23 | 6 | 14.5 | W/m/K |
| Specific heat capacity (Cp) | 480 | 500 | 460 | J/kg/K |
| Young’s coefficient | 140,000 | 160,000 | 207,000 | Mpa |
| Curie temperature | 570 | 560 | 980 | °C |
| Yield stress | 800 | 200 | 393 | Mpa |
| Density | 7,300 | 7,500 | 8,110 | kg/m3 |
| Electrical resistivity | 1.2E−6 | 20E−6 | 4.06E−7 | Ω/m |
Comparative thermal parameters and cooling techniques of conventional and proposed aerospace generators
| Thermal parameter | Conventional aerospace generators | Proposed aerospace generators | Unit |
|---|---|---|---|
| Winding loss | 450.7 | 232.5 | (W) |
| Iron loss – stator core | 226.6 | 0.6027 | (W) |
| Iron loss – rotor core | 0.3087 | 0.02588 | (W) |
| Magnet loss | 29.53 | 33.82 | (W) |
| Additional loss | 29.83 | 29.42 | (W) |
| Total loss | 737 | 296.4 | (W) |
| Total thermal loss | 637.4 | 165.4 | (W) |
| Max winding temperature | 142 | 89 | (°C) |
| Max stator temperature | 168.4 | 92.5 | (°C) |
| Max rotor temperature | 157.9 | 88.1 | (°C) |
| Thermal limit margin | 15 | 42 | % |
| Thermal conductivity of core | 14.5 | 23 | |
| Cooling mechanism | Passive convection | Directed forced air |
Key geometric design parameters of the proposed aerospace generator_
| Parameter | Value | Unit |
|---|---|---|
| Number of stator slots | 9 | |
| Number of poles | 6 | |
| Stator outer diameter | 120 | mm |
| Shaft diameter | 30 | mm |
| Airgap length | 2 | mm |
| Magnet thickness | 7 | mm |
| Banding thickness | 1 | mm |