AeroForge: A Comprehensive Framework for Aluminium-Ion Battery Systems with Silicon Carbide Integration Enabling Ultra-Long-Range Electric Aviation

AeroForge: A Comprehensive Framework for Aluminium-Ion Battery Systems with Silicon Carbide Integration Enabling Ultra-Long-Range Electric Aviation | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article AeroForge: A Comprehensive Framework for Aluminium-Ion Battery Systems with Silicon Carbide Integration Enabling Ultra-Long-Range Electric Aviation Divyansh Kumar Singh This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7383327/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract Purpose: The transition to sustainable aviation requires revolutionary advances in energy storage and system integration. This paper presents AeroForge, a novel theoretical framework that combines aluminium-ion (Al-ion) batteries with silicon carbide (SiC) enhancement and multi-modal energy harvesting for electric aircraft, targeting ranges of 5,000-10,000 km. The framework addresses the critical gap in ultra-long-range electric aviation by systematically integrating emerging technologies with rigorous uncertainty quantification. Methods: The AeroForge framework integrates assumed 600 Wh/kg Al-ion battery packs with SiC nanowire enhancement, modelled to achieve moderate system efficiency through advanced power management. Multimodal energy harvesting incorporates micro ram-air turbines, piezoelectric arrays, and photovoltaic skin. Comprehensive Monte Carlo analysis (N=2,000) models range under assumed parameter distributions, while physics-based thermal modelling evaluates operation during 6-hour flight profiles. Economic analysis projects the levelized cost of energy and lifecycle savings. Results: Framework models indicate mean ranges of approximately 5,000 km with 50% probability of achieving 5,000+ km. Energy harvesting contributes an estimated 25 kW continuous power, extending range by 10-15%. Thermal modelling demonstrates safe operation with maximum cell temperatures of 78°C and SiC electronics at 165°C. Economic analysis reveals a projected levelized cost of energy at $0.127/kWh with estimated 47% lifecycle cost savings versus conventional aircraft. Conclusion: AeroForge provides a promising pathway for ultra-long-range electric aviation by combining advanced batteries, materials, and harvesting technologies. The integrated approach with uncertainty quantification highlights potential for revolutionary efficiency gains and cost reductions, paving the way for sustainable air travel. Aeronautics and Astronautics Aluminium-ion batteries Electric aviation Energy harvesting Monte Carlo analysis Silicon carbide Sustainable transportation Thermal management Ultra-long-range aircraft Full Text Additional Declarations The authors declare no competing interests. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7383327","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":501095322,"identity":"1e8de2cb-ce85-4410-afe5-a7840289fe61","order_by":0,"name":"Divyansh Kumar Singh","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA3klEQVRIiWNgGAWjYNACAwYGfobDB4AsCRnitUg2HksAaeEhwaLDZwxANGEt/NLNxx7zFNgkzmw78/nVjRoLHgb2w0c34NMiOedYujGPQVpiP8/ZbdY5x4AO40lLu4HXPTdyzCRnGBzOnTnj7DbjHDagFgkeMwJa8r8BtfzP3XD/zTPjnH9EaQGa/MHgQO6GA2eYH+e2EaEF6BczoJbk+pkNx8yYc/skeNgI+QUYYs8kEv7YGQOj8vHnnG91cvzsh4/h1cIggWCygdlseJWjaWH+QFD1KBgFo2AUjEgAAJ7XSuFq0KZpAAAAAElFTkSuQmCC","orcid":"https://orcid.org/0009-0007-5605-447X","institution":"Independent","correspondingAuthor":true,"prefix":"","firstName":"Divyansh","middleName":"Kumar","lastName":"Singh","suffix":""}],"badges":[],"createdAt":"2025-08-15 17:56:19","currentVersionCode":1,"declarations":{"humanSubjects":false,"vertebrateSubjects":false,"conflictsOfInterestStatement":false,"humanSubjectEthicalGuidelines":false,"humanSubjectConsent":false,"humanSubjectClinicalTrial":false,"humanSubjectCaseReport":false,"vertebrateSubjectEthicalGuidelines":false},"doi":"10.21203/rs.3.rs-7383327/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7383327/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":89347321,"identity":"b486986c-6beb-497c-b88a-f36658513ad3","added_by":"auto","created_at":"2025-08-19 05:12:24","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1133353,"visible":true,"origin":"","legend":"","description":"","filename":"aeroforgeaia.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7383327/v1_covered_2a534c3d-94b1-47fd-9bb7-1ef719136924.pdf"}],"financialInterests":"The authors declare no competing interests.","formattedTitle":"\u003cp\u003eAeroForge: A Comprehensive Framework for Aluminium-Ion Battery Systems with Silicon Carbide Integration Enabling Ultra-Long-Range Electric Aviation\u003c/p\u003e","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":true,"hideJournal":true,"highlight":"","institution":"None","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Aluminium-ion batteries, Electric aviation Energy, harvesting Monte Carlo, analysis Silicon carbide, Sustainable transportation, Thermal management, Ultra-long-range aircraft","lastPublishedDoi":"10.21203/rs.3.rs-7383327/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7383327/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003ePurpose: The transition to sustainable aviation requires revolutionary advances in energy storage and system integration. This paper presents AeroForge, a novel theoretical framework that combines aluminium-ion (Al-ion) batteries with silicon carbide (SiC) enhancement and multi-modal energy harvesting for electric aircraft, targeting ranges of 5,000-10,000 km. The framework addresses the critical gap in ultra-long-range electric aviation by systematically integrating emerging technologies with rigorous uncertainty quantification.\u003c/p\u003e\n\u003cp\u003eMethods: The AeroForge framework integrates assumed 600 Wh/kg Al-ion battery packs with SiC nanowire enhancement, modelled to achieve moderate system efficiency through advanced power management. Multimodal energy harvesting incorporates micro ram-air turbines, piezoelectric arrays, and photovoltaic skin. Comprehensive Monte Carlo analysis (N=2,000) models range under assumed parameter distributions, while physics-based thermal modelling evaluates operation during 6-hour flight profiles. Economic analysis projects the levelized cost of energy and lifecycle savings.\u003c/p\u003e\n\u003cp\u003eResults: Framework models indicate mean ranges of approximately 5,000 km with 50% probability of achieving 5,000+ km. Energy harvesting contributes an estimated 25 kW continuous power, extending range by 10-15%. Thermal modelling demonstrates safe operation with maximum cell temperatures of 78°C and SiC electronics at 165°C. Economic analysis reveals a projected levelized cost of energy at $0.127/kWh with estimated 47% lifecycle cost savings versus conventional aircraft.\u003c/p\u003e\n\u003cp\u003eConclusion: AeroForge provides a promising pathway for ultra-long-range electric aviation by combining advanced batteries, materials, and harvesting technologies. 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