Research on the development, adaptation and durability of 140kW aviation hydrogen internal combustion engine for general aviation

In response to the escalating challenge of global aviation carbon emissions, this research presents the comprehensive development and experimental validation of a 140-kW hydrogen internal combustion engine specifically engineered for general aviation applications. The engine achieves a 76.5% power increase relative to the baseline 80 kW automotive-derived hydrogen engine, delivering 141.4 kW at 4800 rpm, facilitated by a strategic reduction in compression ratio from 12.5 to 10.6 to mitigate risks of abnormal combustion. Core technological advancements include a new high-pressure hydrogen injection system at 12 MPa, a turbocharger rematched to address hydrogen's low exhaust gas enthalpy, a lean combustion control strategy enabling NOx emissions below 100 ppm at the cruising condition, and a dry-sump lubrication system ensuring reliable operation under dynamic flight attitudes. A rigorous 152-hour endurance test and 4-hour tilting validation under ±45° in pitch and roll axes confirmed system durability, with piston ring wear under 7 μm and consistent oil pressure between 300–700 kPa. Performance results demonstrated an efficiency reaching 35.3%, stable combustion across operational conditions, and a practical aircraft range extension to 450 km with zero carbon emissions flight. This study establishes a foundation for the deployment of hydrogen propulsion in aviation, offering a pathway toward sustainable air transportation and the green aviation.