Session: 19-05: Design, control, and testing.

Submission Number: 177929

Development of an Electric-Ducted-Fan Based Propulsion System – From Concept to Validation 

With the growing global demand for sustainable and energy-efficient aviation technologies, the Electric Ducted Fan (EDF) has emerged as a promising propulsion concept for future aircraft due to its high efficiency, low noise, and structural adaptability. EDF propulsion systems combine the aerodynamic efficiency of axial fans with the noise suppression and safety advantages of a surrounding duct, making them particularly suitable for distributed electric propulsion configurations in next-generation green aviation platforms.

Despite their potential, aerodynamic studies of EDFs continue to face significant challenges. Full-scale experimental testing remains costly and technically complex, limiting the availability of reliable datasets for model development and validation. Consequently, Computational Fluid Dynamics (CFD) simulations have become the primary tool for aerodynamic performance evaluation. However, establishing consistency between numerical predictions and experimental data remains essential to ensure modeling fidelity and guide design optimization.

This study documents a complete development roadmap for a ducted-fan-based propulsion system, encompassing conceptual design, aerodynamic evaluation, and experimental validation. A 120 mm-diameter EDF prototype was designed and manufactured, integrating the motor, rotor, stator, and duct into a compact and efficient configuration. The rotor–stator blade profiles were selected based on aerodynamic performance criteria derived from low-speed fan design studies, and the structural integrity of the assembly was verified to ensure mechanical reliability under design loads.

For aerodynamic performance evaluation, a single-passage steady-state CFD approach was employed using ANSYS Workbench. High-quality structured meshes were generated with Turbogrid, and the SST turbulence model was used within the CFX solver. The single-passage method, employing periodic boundary conditions, accurately replicates the full-annulus flow while significantly reducing computational cost. Simulations were conducted at six rotational speeds—100%, 95%, 90%, 80%, 60%, 40% of the design speed—to analyze variations in efficiency and total pressure ratio with mass flow rate. Outlet backpressure was varied to extend the operating range toward stall, enabling the construction of a comprehensive aerodynamic performance map.

Finally, an integrated experimental test rig was developed to support future validation. The setup enables precise measurement of key parameters such as power, thrust, pressure distribution, and flow characteristics under controlled operating conditions. The system incorporates a calibrated flow meter, a high-precision thrust sensor, and a traversing mechanism for detailed flow-field measurements. Although experimental testing is still under preparation, the system provides a robust foundation for subsequent validation and refinement.

Overall, this work establishes a systematic roadmap for the design, build, evaluation, and testing of ducted-fan-based propulsion systems, providing an efficient and replicable framework to accelerate future EDF innovation and development.

Presenting Author: Ziyu Liu Institute for Aero Engine, Tsinghua University

Presenting Author Biography: Liu Ziyu is currently a Ph.D. student at the Institute for Aero Engine, Tsinghua University. He received his Bachelor’s degree in Engineering Mechanics from Beijing Institute of Technology. His research interests include turbomachinery aerodynamics, electric ducted fan propulsion, and numerical simulation of compressor flow fields.

Authors:

Ziyu Liu Institute for Aero Engine, Tsinghua University
Yufei Zhu Institute for Aero Engine, Tsinghua University
Fangyuan Lou Institute for Aero Engine, Tsinghua University