Ram air–based thermal management systems (TMS) are investigated herein for the cooling of future hybrid-electric aircraft. The developed TMS model consists of all components required to estimate the impacts of mass, drag, and fuel burn on the aircraft, including heat exchangers, coldplates, ducts, pumps, and fans. To gain a better understanding of the TMS, one- and multi-dimensional system sensitivity analyses were conducted. The observations were used to aid with the numerical optimization of a ram air–based TMS towards the minimum fuel burn of a 180-passenger short-range partial-turboelectric aircraft with a power split of up to 30% electric power. The TMS was designed for the conditions at the top of the climb. For an aircraft with the maximum power split, the additional fuel burn caused by the TMS is 0.19%. Conditions occurring at a hot-day takeoff represent the most challenging off-design conditions for TMS. Steady-state cooling of all electric components with the designed TMS is possible during a hot-day takeoff if a small puller fan is utilized. Omitting the puller fan and instead oversizing the TMS is an alternative, but the fuel burn increase on aircraft level grows to 0.29%.

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Providing sufficient cooling power for an aircraft will become increasingly challenging with the introduction of (hybrid-) electric propulsion. To avoid excessive drag from heat exchangers, the heat sink potential of the aircraft surface is evaluated in this study. Semi-empirical correlations are used to estimate aircraft surface area and heat transfer. The impact of surface heating on aircraft drag is qualitatively assessed. Locating surface heat exchangers where fully turbulent flow is present promises a decrease in aircraft drag. Surface cooling potential is investigated over a range from small regional aircraft to large wide body jets and a range of surface temperatures. Four mission points are considered: Take-off, hot day take-off, climb and cruise. The results show that surface heat exchangers can provide cooling power in the same order of magnitude as the waste heat expected from (hybrid-) electric drive trains for all sizes of considered aircraft. Also, a clear trend favouring smaller aircraft with regards to the ratio of available to required cooling power is visible.

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