An aero-structural algorithm to reduce the energy consumption of a propeller-driven aircraft is developed through a propeller design method coupled with a Particle Swarm Optimization (PSO). A wide range of propeller parameters is considered in the optimization, including the geometry of the airfoil at each propeller section. The propeller performance prediction tool employs a convergence improved Blade Element Momentum Theory fed by airfoil aerodynamic characteristics obtained from XFOIL and a validated OpenFOAM. A stall angle correction is estimated from experimental NACA 4-digits data and employed where convergence issues emerge. The aerodynamic data are corrected to account for compressibility, three-dimensional, viscous, and Reynolds number effects. The coefficients for the rotational corrections are proposed from experimental data fitting. A structural model based on Euler-Bernoulli beam theory is employed and validated against Finite Element Analysis, while the impact of centrifugal forces is discussed. A case of study is carried out where the chord and pitch distributions are compared to minimal losses distribution from vortex theory. Wind tunnel tests were performed with printed propellers to conclude the feasibility of the entire routine and the differences between XFOIL and CFD optimal propellers. Finally, the optimal CFD propeller is compared against a commercial propeller with the same diameter, pitch, and operational conditions, showing higher thrust and efficiency.

An aero-structural algorithm to optimize a flying wing in cruise conditions for preliminary design is developed using two-way interaction between the structure and aerodynamics. A particle swarm routine is employed to solve the multi-objective optimization, aiming to reduce the weight of the structure and the aerodynamic drag at the design point. Different shapes are evaluated during the optimization process until the algorithm reaches the optimal wing aspect ratio, taper ratio, angle of incidence, twist angle, swept angle, and airfoil shape, where a six-parameters method is employed to allow reflex airfoils. A main isotropic I-beam models the wing structure. An extended vortex lattice model is employed to model the aerodynamics, along with a high-order panel method with fully coupled viscous interaction. The finite element method is used to solve the flying-wing structure under static loads. An algorithm is developed to iterate between the deflection of the wing and its impact on the aerodynamics until convergence is reached. Different constraints are implemented into the objective function to fulfil the structural criteria and the longitudinal static stability. A comparison against a baseline optimization is carried out, achieving higher efficiency and promising results in elliptical lift distribution, and a high static margin, without the use of non-constant twist. The results suggest that combining both reflex airfoils and sweep with washout is the optimal solution to reduce the drag and weight, keeping the longitudinal static stability criteria for tailless aircraft in the lower end of the transonic regime.