General Atomics Completes Durability Testing on New 200 Horsepower Heavy Fuel Engine for UAVs

General Atomics has finished durability testing on its new 200-horsepower heavy fuel engine, offering a maintenance-free operational period of 2,500 hours.

General Atomics has successfully completed durability testing on its new 200-horsepower heavy fuel engine (HFE) 2.0. This engine boasts a maintenance-free operational period of 2,500 hours, equivalent to over 100 days of continuous use.

The final test simulated the full operational period under the highest flight loads, including conditions such as 1,250 full-power take-offs and climbs to high cruising altitude, as well as over 200 hours of cruising under worst-case generator loading conditions. 

The HFE 2.0 engine, developed in partnership with General Atomics Europe and propulsion technology innovator Cosworth, includes a new gearbox and dual brushless generators. These features help reduce the engine's field maintenance needs. The dual brushless generators, provided by General Atomics Electromagnetic Systems, offer over 50% more electrical power without increasing the engine's size, weight, or power requirements.

Increased electrical power from the new generators allows for enhanced payloads and supports new mission requirements. General Atomics President David R. Alexander praised the company's Internal Research and Development team for their work on the HFE 2.0 program, highlighting the engine's improved reliability, durability, and ability to address issues with diminishing manufacturing sources for aviation heavy fuel engines and components.

The HFE 2.0 is designed to power the latest General Atomics unmanned aerial system, the Gray Eagle 25M. Additionally, it is being considered as a replacement for the US Army’s current 180-horsepower engine used in the Gray Eagle Extended Range drone. 

Final 150-hour qualification testing of the HFE 2.0 is scheduled to be completed in September, with certification by the US Army expected to follow.

By offering greater power and reduced maintenance, the HFE 2.0 represents a significant advancement in heavy fuel engine technology for unmanned aerial systems.