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

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.