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Design, wind tunnel test, computational fluid dynamics (CFD) analysis, and flight test data analysis are conducted for the propeller of EAV-3, which is a solar-powered high-altitude long-endurance unmanned aerial vehicle developed by Korea Aerospace Research Institute. The blade element momentum theory, in conjunction with minimum induced loss, is used as a basic design method. Airfoil data are obtained from CFD analysis, which takes into account the low Reynolds number effect. The response surface is evaluated for design variables by using design of experiment and kriging metamodel. The optimization is based on desirability function. A wind tunnel test is conducted on the designed propeller. Numerical analyses are performed by using a commercial CFD code, and results are compared with those obtained from the design code and wind tunnel test data. Flight test data are analyzed based on several approximations and assumptions. The propeller performance is in good agreement with the numerical and measurement data in terms of tendency and behavior. The comparison of data confirms that the design method, wind tunnel test, and CFD analysis used in this study are practically useful and valid for the development of a high-altitude propeller.

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