The aerospace industry is on the cusp of a revolution, as the development of sixth-generation aircraft promises to transform air combat and redefine aviation standards. At the heart of this transformation lies the next generation of jet engines, designed to meet the demands of unprecedented speed, agility, efficiency, and stealth. These engines are not just an evolution of current technology but a leap forward, incorporating advanced materials, innovative designs, and cutting-edge technologies.
How Jet Engines Work
All jet engines, which are also called gas turbines, work on the same principle. The engine sucks air in at the front with a fan. The fan is spinning in the front of the engine, which continually draws a large amount of air into the engine. The air is then compressed, mixed with fuel, ignited, and expelled out the back, producing thrust. This process involves several key components:
- Fan: Draws air into the engine.
- Compressor: Increases air pressure. The compressor is made with many blades attached to a shaft. The blades spin at high speed and compress or squeeze the air.
- Combustor: The compressed air is then sprayed with fuel and an electric spark lights the mixture. The burning gases expand and blast out through the nozzle, at the back of the engine.
- Turbine: Extracts energy from the high-pressure, high-temperature air to drive the compressor and fan. As the hot air is going to the nozzle, it passes through another group of blades called the turbine, located near the back of the engine. The turbine is attached to the same shaft as the compressor. Spinning the turbine causes the compressor to spin. The turbine blade extracts the energy from the high pressure and temperature air to keep the fan at the front spinning and drawing in more air. Along the way, power is generated by the spinning components in the engine’s core to charge the electrical components of the aircraft, similar to how your car’s battery is recharged while driving on the interstate.
Jet engines fall into two main categories: low-bypass turbofans (turbojets) and high-bypass turbofans. Turbojets are optimized for high-speed performance, while high-bypass turbofans, which feature a large fan bypassing much of the air around the engine core, are designed for fuel efficiency and are commonly used in commercial aviation.
Turbojets are optimized for high-performance applications, enabling fighter jets to reach speeds above Mach 2 and even propelling the SR-71 “Blackbird” to speeds well over Mach 3, but they are notoriously fuel-inefficient. The performance of a traditional turbojet is primarily driven by the high-pressure engine core, which includes the compressor, combustion chamber, turbine, and exhaust nozzle. In contrast, high-bypass turbofans are the workhorses of commercial aviation, designed for subsonic thrust and fuel efficiency, but they perform poorly at supersonic speeds. These engines feature an oversized fan driven by the jet turbine, which provides additional lower-pressure airflow that bypasses the combustion chamber, functioning much like a large propeller.
The Evolution of Jet Engine Technology
Jet engines are the workhorses of modern aviation, carrying millions of passengers across trillions of miles annually with remarkable reliability. The current generation of jet engines, primarily using gas turbine technology, has evolved significantly since their inception.The target has been to enhance power with reduced size and weight, low maintenance cost and maintenance time, low noise etc. However, as we step into the era of sixth-generation aircraft, the need for more advanced, efficient, and powerful engines has never been more pressing.
Since the introduction of the jet engine in the mid-20th century, there have been significant advancements in propulsion technology. Fifth-generation fighters, such as the F-22 Raptor and F-35 Lightning II, brought about substantial improvements in performance, stealth, and avionics. However, the requirements for sixth-generation aircraft are even more ambitious, necessitating a new breed of jet engines that can provide superior thrust, fuel efficiency, and operational flexibility.
One of the notable developments is the F135-600 engine used in the Joint Strike Fighter, which offers short takeoff and vertical landing (STOL and VTOL) capabilities.
NASA’s HyTEC Initiative
HyTEC, or Hybrid Thermally Efficient Core, is a NASA project initiated in June 2021 aimed at enhancing the sustainability of the aviation industry by developing a highly efficient small core for turbofan jet engines. The project focuses on increasing fuel efficiency and hybridization, enabling more electrical power to be drawn from the engine to power various aircraft systems, similar to how hybrid cars function. This approach not only boosts fuel efficiency but also supports the broader goal of reducing aviation’s carbon footprint. A key aspect of HyTEC’s innovation lies in improving the bypass ratio, which measures the amount of air pushed by the fan as thrust relative to the air entering the engine core. Current GE engines on the Boeing 787 Dreamliner have a bypass ratio of 9, and HyTEC aims to raise this to 15 by shrinking the engine core while keeping the fan size constant, thereby maintaining thrust levels but with greater fuel efficiency.
Achieving this increased bypass ratio requires the development of a smaller, more efficient engine core that can handle higher pressures and temperatures. This necessitates the use of advanced materials such as ceramic matrix composites and environmental barrier coatings, which are currently being tested in NASA Glenn’s materials laboratories and partner facilities to ensure they can withstand the enhanced operational conditions. The project also explores hybridization, increasing the electrical power generated by the engine to improve overall efficiency, similar to how hybrid cars operate.
Additionally, the project explores innovative designs and technologies to maintain performance despite the core’s reduced size. Once these components are validated, the HyTEC team will collaborate with industry partners to build and test a fully operational small-core engine. They aim to significantly increase the electrical power output from these engines, targeting a rise from the current 5% in the Boeing 787 Dreamliner to 10-20%. This increase in electrical power will not only improve the overall efficiency of the engines but also pave the way for more integrated hybrid systems in aviation. Ultimately, NASA hopes to have these advanced propulsion technologies ready for industry adoption within the next decade, pushing the envelope on sustainable aviation.
Key Features of Next Generation Jet Engines
The next generation of military engines will be adaptive, moving from high bypass ratios to low bypass ratios to provide additional performance when necessary, but also optimize performance in cruising modes.
The current advancements in jet engine technology have significantly improved efficiency, maintaining the same basic architecture since the introduction of the high-bypass turbofan almost 50 years ago. However, the US Air Force Research Laboratory (AFRL) indicates that this architecture will not suffice for mid-2030s combat aircraft, which will require engines to support laser weapons and advanced drones, necessitating better power and thermal management. Future military jet engines will need to adapt dynamically, with bypass ratios adjusting based on mission requirements and compressor elements changing shape mid-flight to optimize airflow. Electrical power will be drawn from various compressor sections to fuel high-energy systems like lasers and sensors, with innovative heat storage solutions being developed to manage the resulting thermal load. This shift represents a significant evolution in jet engine design to meet the increasing demands for efficiency, power, and versatility in modern aerial combat.
- Adaptive Cycle Engines (ACE): One of the most groundbreaking innovations in next-generation jet engines is the development of Adaptive Cycle Engines. Unlike traditional jet engines, which operate in a fixed cycle, ACEs can switch between different operational modes depending on the flight conditions. This adaptability allows for optimal performance across a wide range of speeds and altitudes, providing enhanced fuel efficiency and increased thrust when needed.
- Increased Thrust-to-Weight Ratio: Future jet engines aim to achieve a higher thrust-to-weight ratio, which translates to better performance and agility. By utilizing advanced materials like lightweight composites and high-temperature alloys, engineers can reduce engine weight while increasing power output. This results in faster acceleration, higher top speeds, and improved maneuverability, crucial for sixth-generation combat scenarios.
- Stealth Integration: Stealth technology is a critical component of sixth-generation aircraft. Next-generation jet engines are being designed with stealth features, such as reduced radar cross-section and minimized infrared signatures. Advanced cooling techniques and materials are being employed to lower the heat emissions of the engines, making the aircraft less detectable by enemy sensors.
- Fuel Efficiency and Sustainability: With increasing concerns about the environmental impact of aviation, next-generation jet engines are also focusing on fuel efficiency and sustainability. The use of alternative fuels, such as biofuels and synthetic fuels, is being explored to reduce the carbon footprint of military aviation. Additionally, improvements in engine efficiency help extend the operational range of aircraft, reducing the need for frequent refueling.
- Enhanced Durability and Maintainability: The harsh operational environments faced by military aircraft demand engines that are not only powerful but also durable and easy to maintain. Next-generation jet engines incorporate advanced diagnostic systems and predictive maintenance technologies that monitor engine health in real-time. This ensures timely maintenance and reduces the risk of in-flight failures, thereby enhancing the overall reliability and safety of the aircraft.
Technological Innovations Driving the Change
Several promising technologies are being explored to achieve these ambitious goals:
- Adaptive Cycle Engines: These engines could dynamically adjust their compression ratio based on flight conditions, offering improved fuel efficiency at high altitudes and increased thrust during combat maneuvers.
- Variable Bypass Ratio Turbofans: By modifying the amount of air that bypasses the engine core, these engines could optimize performance for different flight regimes, balancing fuel efficiency with thrust.
- Electric and Hybrid Propulsion: While still in their early stages, electric or hybrid propulsion systems could offer significant advantages in terms of silent operation and improved fuel efficiency.
The development of next-generation jet engines is being fueled by several technological innovations:
- Additive Manufacturing (3D Printing): This technology allows for the creation of complex engine components with unprecedented precision and efficiency. It enables the production of lighter, stronger parts that are crucial for improving the performance and durability of jet engines.
- Advanced Materials: The use of ceramics, high-temperature composites, and other advanced materials helps engines withstand extreme conditions while maintaining structural integrity. These materials contribute to weight reduction and enhance the overall performance of the engines.
- Digital Twin Technology: Digital twins are virtual replicas of physical engines that can be used for simulations and testing. This technology allows engineers to optimize engine designs, predict potential issues, and implement solutions before physical prototypes are built, significantly speeding up the development process.
Several energy conversion technologies have been identified or proposed that may have potential for application in commercial aircraft e.g., solar power, nuclear power, battery/fuel cell power, and hydrogen engines. However, these advanced concepts would require major innovations, development, and changes in infrastructure before they could serve as viable alternatives to hydrocarbon-powered gas turbine engines.
A Look at 6th Gen Fighter Engine Developments Around the Globe
The sixth-generation fighter jet is a global endeavor, with various countries vying to develop the most advanced aerial war machine. As nations like the United States, Russia, and Japan develop sixth-generation fighter jets, new engine technologies are being pioneered to meet their advanced requirements. A crucial component of this futuristic aircraft is the engine, and the race is on to create the next generation of jet propulsion systems. Here’s a glimpse into the international landscape of 6th gen fighter engine development
Russia
Russian designers have initiated the development of a sixth-generation fighter jet, as announced by Andrei Grigoryev, the director-general of the Foundation for Advanced Research. This new aircraft is planned to achieve speeds exceeding 11,000 kilometers per hour, demonstrate super-maneuverability, and operate in near outer space. Concurrently, Russia’s United Engine Corporation, part of the state tech corporation Rostec, is beginning R&D on the sixth-generation engine for combat aircraft. According to United Engine Corporation Deputy CEO for Strategy Mikhail Remizov, this effort includes developing technologies for the sixth-generation engine, a combined powerplant, and more electric engine technology.
United States: Leading the Charge with Adaptive Cycle Technology
The US is at the forefront of 6th gen engine development with its Next-Generation Adaptive Propulsion (NGAP) program. This ambitious initiative involves industry giants like GE Aviation and Pratt & Whitney working on prototype engines. These engines are expected to utilize adaptive cycle technology, allowing them to adjust their compression ratio based on flight conditions. This translates to improved fuel efficiency at high altitudes and increased thrust during combat maneuvers – a perfect balance for a versatile fighter jet.
Adaptive Engine Technology Development (AETD) and Adaptive Engine Transition Program (AETP):
These U.S. programs involve GE and Pratt & Whitney developing adaptive cycle engines with a third stream of airflow, which can be adjusted to enhance either fuel efficiency or thrust as needed. GE’s XA100 engine, for example, promises significant improvements in thrust, fuel efficiency, and thermal management.
The Air Force Research Laboratory (AFRL) has been collaborating with GE Aviation and Pratt & Whitney on developing advanced “three-stream” adaptive engine technology under the Adaptive Engine Technology Development (AETD) program. This initiative, part of the broader ADaptive VErsitile ENgine Technology (ADVENT) effort, aims to revolutionize fighter jet engines by incorporating a third, outer flowpath that can be adjusted based on flight conditions. This adaptive cycle engine concept, which began in 2007 with the ADVENT program, continued through the AETD program starting in 2012, and evolved into the Adaptive Engine Transition Program (AETP) in 2016, has laid a robust foundation of design and empirical testing for full-scale prototype engine development.
In an ADVENT engine, the conventional high-pressure core exhaust and low-pressure bypass streams are supplemented by a third bypass duct. This duct can be opened or closed depending on flight conditions, optimizing the engine’s performance. During takeoff, the third stream is closed to decrease the bypass ratio, channeling more airflow through the high-pressure core to maximize thrust. Conversely, during cruising, the third stream is opened to increase the bypass ratio, significantly reducing fuel consumption. This adaptive mechanism can transform the engine from a high-thrust strike configuration to a fuel-efficient transport mode, increasing subsonic range by up to 40% and extending loiter times on target by 60%. The AETP program represents the culmination of these efforts, aiming to bring adaptive cycle engines to operational maturity, with GE standing out as the only company to successfully complete both the ADVENT and AETD programs, solidifying its leadership in this groundbreaking technology.
The Advanced Turbine Technology for Affordable Mission Capability (ATTAM) Phase I Program is a collaborative effort involving the Department of Defense (DoD), NASA, the Department of Energy (DOE), the Federal Aviation Administration (FAA), and industry partners. Launched in 2026, this initiative aims to develop groundbreaking technologies that enhance fuel efficiency, propulsive capability, and power and thermal management in turbine engines. ATTAM is the latest in a series of engine development programs dating back 29 years, starting with the Integrated High-Performance Turbine Engine Technology (IHPTET) from 1987 to 2005, which led to significant advancements in thrust and power with engines like the Pratt & Whitney F119 and F135. The subsequent program, Versatile Affordable Advanced Turbine Engines (VAATE), focused on improving power while reducing development and maintenance costs.
The ATTAM Phase I program sets ambitious goals, aiming to increase fuel efficiency by 10%-30%, enhance power and thermal management capabilities by 2x to 20x, and boost propulsive capability by 10%-25%, depending on the engine class. This program will be closely integrated with the Air Force Research Laboratory’s (AFRL) aircraft-based efforts, including the Energy Optimised Aircraft and the Megawatt Tactical Aircraft Initiative. Building on VAATE initiatives, ATTAM will pursue further advancements, such as adaptive bypass flow jet engines demonstrated by GE Aviation and Pratt & Whitney, which could be integrated into the Lockheed Martin F-35A to increase its range by up to 25%. Additionally, the ADAPT program will refine advanced compressor technology with variable stator vanes for mobility aircraft. To support these advancements, materials like temperature-resistant metallics and ceramic matrix composites will be adapted to withstand higher temperatures in the engine core. The overarching challenge for ATTAM will be integrating propulsion systems with onboard power systems to optimize overall performance, even if it requires sub-optimizing individual components. This holistic approach emphasizes the importance of collaboration between propulsion and power and energy communities.
Kratos Defense & Security Solutions announced in June 2021 that its Kratos Turbine Technologies (KTT) division successfully completed a core engine test campaign, demonstrating key performance and operability targets in partnership with the AFRL’s Turbine Engine Division (AFRL/RQT). This milestone supports the development of affordable powerplants for future munitions and attritable unmanned aerial vehicles (UAVs), showcasing the potential of innovative turbine technologies under the ATTAM initiative.
Rolls-Royce’s UltraFan: Advancing Aviation Technology
Reaction Engines Begins Testing High-Mach Propulsion Technology
Still in development, SABRE (Synergetic Air-Breathing Rocket Engine) aims to enable hypersonic flight at speeds exceeding Mach 5. Its key component, the Precooler, allows high-Mach engines to function more efficiently, potentially revolutionizing both atmospheric and space propulsion.
Since the contract award in mid-2021, the Reaction Engines US team has made substantial progress. The planned tripling of the heat load necessitated several system upgrades at the TF2 high-temperature test site at the Colorado Air and Space Port. The team has successfully navigated all design milestones and integrated new hardware, demonstrating rapid advancement towards operational readiness.
In July 2022, Reaction Engines, in collaboration with the Air Force Research Laboratory (AFRL), initiated a new phase of testing for its high-Mach propulsion technology under the Foreign Comparative Testing (FCT) Program. This new test campaign, led by Reaction Engines US, aims to build upon the previous success of the HTX test program by significantly increasing the air mass flow rate and other test parameters. These enhancements will result in a three-fold increase in the total energy transfer through the engine heat exchanger. The selected test points are designed to demonstrate the integration of Reaction Engines’ thermal management technology with state-of-the-art jet engines. Central to this effort is the company’s SABRE (Synergetic Air-Breathing Rocket Engine) technology, particularly its groundbreaking Precooler, which enables high-Mach engines to operate more efficiently. SABRE, still under development, promises to enable hypersonic flight at speeds exceeding Mach 5 and has potential applications in space propulsion.
Europe: France, Germany, and Spain Collaborate on the Future Combat Air System (FCAS)
The European consortium behind the FCAS program is also developing a new engine for their 6th gen fighter concept. While specific details are limited, Safran, a leading French aerospace company, is expected to play a major role in engine development. France has experience with the Safran M88 engine powering the Rafale fighter, and this expertise will likely be leveraged in the FCAS engine design. Integration with future European fighter designs and potential technology sharing with partner nations like Germany and Spain will be key considerations.
The integration of next-generation jet engines into sixth-generation aircraft is set to revolutionize air combat. These engines will enable aircraft to perform a broader range of missions with greater efficiency and effectiveness. From supersonic speeds to long-endurance patrols, the versatility of these engines will provide military forces with a strategic advantage in various combat scenarios.
“The future will continue to see different and diverging requirements for the military and commercial sectors. Variable mission and adaptive capabilities will drive military programs, while time on wing and efficiency will continue to be the drivers for commercial aircraft. Material choices will differ with the technological and engineering trade-offs within each sector, and the portfolio of materials for aircraft engines will continue to grow with additional research and development, says Ernest ,” said Arvai at Pratt and Whitney
Moreover, the advancements in stealth and sustainability will make sixth-generation aircraft not only formidable in combat but also more environmentally responsible. As nations around the world invest in the development of these cutting-edge technologies, the future of aviation looks set to soar to new heights.
Conclusion
As we approach the era of sixth-generation aircraft, the development of next-generation jet engines is pivotal. These engines will not only push the boundaries of speed, efficiency, and performance but also incorporate advanced materials and adaptive technologies to meet the diverse demands of future aviation. With their adaptive capabilities, enhanced performance, stealth integration, and focus on sustainability, these engines represent a significant leap forward in aerospace technology. From NASA’s HyTEC project to international collaborations and innovative concepts like Boeing’s fusion engine, the future of jet propulsion promises to be a fascinating leap forward in aerospace technology. As research and development continue to push the boundaries of what is possible, the next decade promises to be an exciting era for military aviation, heralding a new age of air superiority and innovation.
References and resources also include:
https://govtribe.com/project/advanced-turbine-technologies-for-affordable-mission-capability-attam-i
http://www.nextbigfuture.com/2015/07/boeings-fusion-fission-hybrid.html
https://www.aerotime.aero/27428-safran-contracted-to-speed-up-fcas-engine-development
https://www.inceptivemind.com/reaction-engines-begins-testing-high-mach-propulsion-technology/25391/