5.
EXPERIMENTAL RESULTS AND ANALYSIS
This section presents the results from structured flight testing of the hybrid-electric Dornier 228
aircraft. Performance parameters, aerodynamic characteristics, and power system behavior are
analyzed to evaluate both operational effectiveness and technological maturity of the retrofitted
platform.
5.1 Performance Data
Recent test flights demonstrated the aircraft’s ability to achieve key operational benchmarks under
hybrid-electric propulsion. The maximum indicated airspeed (IAS) recorded was 230 knots, with
a dual-engine climb rate of 1,200 ft/min. When operating solely on the ZA600 hydrogen-electric
motor, the aircraft maintained a climb rate of 600 ft/min up to 5,000 feet, and a cruise endurance
of approximately 35–40 minutes.
Table 1. Performance Metrics (Hybrid-Electric Configuration)
Parameter Value
Max Airspeed (IAS) 230 knots
Max Climb Rate (Both Engines) 1,200 ft/min
Climb Rate (ZA600 Only) 600 ft/min to 5,000 ft
Cruise Endurance (Hybrid) 35–40 minutes
Cruise Range ~70 NM (electric-only mode)
5.2 Aerodynamic Insights
Flight testing confirmed improved lift characteristics and stable control at high flap deflections.
Stall speeds were notably reduced under full flap conditions, enhancing the aircraft’s short takeoff
and landing (STOL) performance. Data collected at 30° flap deflection yielded a maximum lift
coefficient (CLmax) of approximately 3.1, with stall occurring around 17° angle of attack
(AoA).
Figure 1. Lift vs. Angle of Attack (30° Flap Configuration)
This graph shows how lift coefficient increases with AoA until stall occurs at approximately 17°,
where the curve peaks. This validates earlier wind tunnel projections and confirms safe stall
margins even under hybrid-electric propulsion.
5.3 Technological Evaluation
The hydrogen-electric ZA600 powertrain showed several advantages over legacy turboprop
engines:
Fuel Efficiency: ~20% improvement in equivalent energy consumption per nautical mile
Noise Reduction: ~6 dB lower cabin noise during electric-only cruise
Emissions: Zero CO₂ and NOₓ emissions during electric operation
However, these benefits were accompanied by operational constraints:
Thermal Load: Fuel cell temperatures peaked at 85°C, nearing design thresholds
Redundancy Needs: A fallback conventional engine remains necessary due to current
limitations in sustained power delivery and stack durability
5.4 Operational Challenges and Reliability
Flight testing highlighted the following challenges:
Thermal Creep: Sustained high-power climbs at ambient temperatures above 25°C led to
rapid fuel cell heating
Voltage Transients: Power fluctuations of ±8% were observed during abrupt throttle
inputs
Emergency Events: One flight required intervention due to stack overpressure triggering
a shutdown fail-safe
These findings stress the importance of improved thermal management, controller tuning, and
high-fidelity monitoring systems.
5.5 Visual Analysis
To evaluate thrust performance across altitudes, comparative tests were conducted for both
propulsion systems.
Figure 2. Thrust vs. Altitude (Electric vs. Turboprop)
This chart illustrates how the ZA600 electric motor maintains competitive thrust levels at low to
mid altitudes but experiences a sharper decline above 7,000 feet compared to the turboprop. This
suggests optimal deployment of hydrogen-electric configurations within regional altitudes
below 10,000 feet.
Summary
The hybrid-electric Dornier 228 test flights confirm the feasibility of integrating sustainable
propulsion without compromising core performance. While early results are promising, achieving
commercial reliability will require system refinements—especially in thermal control, redundancy,
and power regulation. These findings support ongoing development and contribute to future
certification frameworks under evolving EASA and FAA standards.
