The rapid development of Autonomous Underwater Vehicles (AUVs) has increased the demand for propulsion systems that balance thrust density, hydrodynamic efficiency, and acoustic discretion. This study presents a comprehensive numerical investigation of the performance of the Blue Robotics T500 thruster, embedded within the RAS-HA-X25 AUV’s internal conduit. Using transient Computational Fluid Dynamics (CFD) within the OpenFOAM framework, this research assesses the propulsive characteristics of the thruster across six distinct outlet geometries, including convergent jet nozzles and multi-lobed “daisy” configurations. To improve computational efficiency for parametric design, a calibrated actuator disc model was developed and validated against resolved-rotor simulations, revealing a 15% discrepancy attributed to tip leakage and hub vortex effects. Results show that at the operational advance ratio (J=0.167), the 60 mm convergent nozzle is the optimal configuration for maximising thrust, achieving a peak net thrust of 42 N. In contrast, the daisy-type lobed geometries, while causing a 50% reduction in absolute thrust compared to a standard cylindrical pipe, significantly homogenise the exit-plane velocity distribution and reduce swirl intensity. These findings indicate that lobed terminations provide a viable mechanism for reducing hydroacoustic signatures, offering a strategic “stealth” advantage for low-observable underwater platforms where acoustic discretion is prioritised over pure thrust density. This study establishes a robust methodology for optimising embedded propulsion modules in next-generation autonomous and hybrid underwater vehicles.
Grm et al. (Tue,) studied this question.