Multi scale systematisation of damage and failure modes of high-pressure hydrogen composite vessels in aviation, Part 2: Analysis

The realisation of hydrogen aviation requires hydrogen storage vessels with increased gravimetric storage density. To achieve this, while meeting the high safety standards of aviation, uncertainties in the development of compressed gaseous hydrogen (CGH 2 ) storage vessels must be reduced. The systematisation methodology proposed in Part 1 of this paper is applied to an exemplary B2 aircraft according to DO-160 with a CGH 2 vessel integrated in an external nacelle under the wing. A systematisation of potentially occurring load cases, corresponding stresses and resulting failure modes of CGH 2 vessels in aircraft is carried out along the length scales from the aircraft super-system to the material level. This in-depth analysis demonstrates the multi-scale propagation and superposition of multiple effects influencing the CGH 2 vessel reliability. It is demonstrated how engineering measures can be implemented at various length scales in order to increase the reliability. The performed analysis provides the basis for identifying measures to improve the reliability/mass ratio compared to current CGH 2 vessels. • Safety-relevant effects along the length scales are identified and systematised. • In-depth multi-scale analysis of loads, stresses, damage and failure modes. • New design paradigms enable the reduction of uncertainties and mass. • Engineering measures on various length scales to mitigate failures.