Don,
This is a great subject that I make sure my student pilots understand before solo.
Most normally aspirated engines are rated at maximum RPM, sea level, standard day. It’s the standard by which we can compare one engine to another on “rated” output. There may be some engines out there rated differently but I’ve not run across one in 46 years of hangar flying.
Normal cruise by definition is something less than max cruise. Let’s use the O-200 in a Cessna 150 for an example.
The O-200A engine is rated for 100 hp at 2750 RPM. It isn’t possible to get 2750 during normal takeoff and normal climb because there is too much load on the prop when the airspeed is low. In cruise at 2500 feet the manual shows max power at 2750 RPM resulting in 92% bhp.(or 92 hp if you like). Because cruise airspeed is faster than climb and the loading on the prop is less, the RPM could exceed maximum allowable with full throttle..In this case the engine is not power limited, but RPM limited. The throttle must be reduced to keep the engine from over speed. This is pretty much true for all fixed pitch prop engines. But it is possible to get nearly the rated power at 2500 feet.
If we had a cruise prop installed we might be able to get full throttle without exceeding 2750 but the altitude and induction losses will rob about 3 inches of manifold pressure. The maximum power available might be 95% or so.
As altitude increases the throttle cannot compensate for the drop in
atmospheric pressure and the power starts to fall off rapidly above 5000 feet. By 7500 feet the power is down to 74% with full throttle and 2700 RPM.
Also note that just because the engine is spinning at 2750 RPM it does not mean it is producing 100%. Pull the power back to idle and shove the nose over. The RPM increases but there is no actual increase in power.
Both Continental and Lycoming small engines are rated for 100% power continuous. That means you may run it at full power for climb and cruise without a time limit. It’s not very economical on fuel and won’t give the best range unless you are bucking a strong headwind. But, if the manufacturer says continuous, then you can run it that way all day if other parameters are not exceeded. As always you must not exceed the RPM redline.
In the case of a conversion engine, anything goes. On my Corvair engine I have put a redline of 3200 RPM continuous because that is where it produces 100 HP. (3200rpm*165 lb-ft / 5252= 100.53 hp.) It is also loafing at that speed whereas the original redline from GM was set at 5500 RPM.
John Pitkin
Greenville, TX