Pratt & Whitney Canada has tested its RTX Hybrid-Electric Flight Demonstrator’s integrated propulsion system and batteries to full power. The system combines a thermal engine with a 1 MW electric motor from Collins Aerospace. This marks the first battery-powered operation of the propulsion system.

Ground testing is underway in Longueuil, Quebec. Future flight testing of the De Havilland Canada Dash 8-100 experimental aircraft will be supported by AeroTEC, which joins De Havilland Aircraft of Canada, GKN Aerospace and Ricardo on the project.

The 200 kWh batteries were supplied by H55 and have been successfully charged and discharged using a Mobile Charging Unit co-developed by Pratt & Whitney Canada, the National Research Council of Canada and the Innovative Vehicle Institute. H55 is backed by RTX Ventures.

Pratt & Whitney Canada’s Jean Thomassin says: “Performing end-to-end tests of our pioneering hybrid-electric propulsion system and batteries marks another critical milestone toward our goal of demonstrating this promising technology in flight. Ultimately, we are targeting up to 30% improved fuel efficiency compared to today's regional turboprops, and insights from this project are also helping us advance the development of hybrid-electric technology to address multiple future platforms.”

AeroTEC president Justin Morigeau adds: “AeroTEC’s mission is to accelerate the evolution of aerospace, and our collaboration with Pratt & Whitney Canada on the RTX Hybrid-Electric Flight Demonstrator project is a clear example of that commitment. In our role leading the modification and flight testing of the experimental aircraft, we're proud to support the demonstration of cutting-edge technologies that will define the future of sustainable flight.”

Hybrid-electric propulsion is a core element of RTX’s roadmap, with the Dash 8 project complemented by the Clean Aviation SWITCH project, where a hybrid-electric Pratt & Whitney GTF engine demonstrator is under development.

Meanwhile US-based Pratt & Whitney Military Engines, also an RTX business, has successfully completed a series of tests on its 3D printed TJ150 turbine wheel. Positive test results mark a significant step forward in additive manufacturing capabilities as the turbine wheel is one of the first rotating parts to be 3D printed.

The miniature TJ150 is a compact, high-performance turbojet engine that can be manufactured quickly and has proven reliability. With 150-pounds of thrust, it is designed to power a variety of autonomous systems and weapons.

"Today we're fielding and flying static engine parts. Rotating engine components, especially for expendable class applications, is the next step," says Chris Hugill, executive director of Pratt & Whitney GatorWorks. "Our testing confirms we're on track with the engine performing at full operating speeds and temperatures and meeting expected life duration. This technology is transforming how we design, develop and deliver capabilities faster."

Pratt & Whitney GatorWorks was the driving force behind the initial TJ150 redesign, drawing on close collaboration between its technical and manufacturing teams and the RTX Technology Research Center. Leveraging a process called unitization, engineers decreased core module part count from over 50 to just a handful, significantly reducing production time and cost. Using in-house capability, they designed and tested the engine within eight months. This latest round of testing marks a significant step moving from static structures to rotating hardware.