Design and Analysis of Hydrogen Storage Tank for Small Aircraft

Hydrogen, a chemical element with a high energy density of approximately 120 MJ/kg, presents significant potential as an alternative fuel for aviation. However, its low volumetric density poses a critical challenge, necessitating large storage tanks to accommodate sufficient fuel for practical use. This study aims to design a hydrogen storage system specifically for light aircraft, focusing on the widely used Cessna 172. The proposed design considersevaluating three materials: aluminum, titanium, and steelalloys, under operational pressures of 200 bar and 300 bar. These materials were selected based on their compatibility with existing manufacturing processes to ensure cost-effectiveness. The storage tank features a cylindrical body with spherical domes at both ends to optimize structural integrity and minimize weight. Dimensions are tailored to fit the Cessna 172 cabin, with the tank positioned in the aircraft’s rear section. Simulation results using SolidWorks revealed that aluminum alloy 2014-T6, while lightweight, experienced the highest stress, strain, and displacement, requiring reinforcement for high-pressure applications. Titanium Alloy Ti-6Al-4V showed a promisingbalance between strength and weight,although it is heavier compared to aluminum alloy.On the other hand, Steel Alloy ASTM A514 demonstrated superior strength but was impractically heavy for small aircraft. Overall, thestudy highlights the limitations posed by the mass of these pressure vessels, emphasizing the need forreinforcements,alternative lightweight materials or composite designs.