Computational thermo-mechanical modelling and design-space exploration of cryogenic hydrogen tanks for aviation

A tool for parametric finite element modelling and analysis of tanks for aviation is developed. Passively insulated cryogenic composite sandwich pressure vessels are investigated, as they conjugate simplicity, effectiveness and lightweight design for aeronautical applications. Several parametric analyses are performed with the aim of gaining both general and case-specific understanding of how particular design choices may impact the tank mechanical and thermal performance. Differently from most of previous studies, multiple design choices, including tank walls thicknesses, constraints for airframe integration strategies, as well as the presence, position and integration of refuelling cutouts and anti-sloshing bulkheads are considered. The thermo-mechanical analyses are performed considering first a simple reference configuration, with the aim of evaluating possible directions for performance enhancement. Results indicate how different design features affect the gravimetric and thermal efficiency of the tank, without compromising structural integrity if the walls thicknesses are suitably sized. The effects of different constraints and geometric discontinuities, which reflect specific fuselage integration choices, must be carefully assessed, as they reduce safety margins. Ultimately, a vessel model including features necessary for safe operation is presented as it serves as a baseline for further optimization. • A tool for parametric FE modelling and analysis of aircraft liquid hydrogen tanks. • Passively insulated fibre composite reinforced tanks are considered and analyzed. • In-depth sensitivity analysis for assessing the tanks thermo-mechanical performance. • Pragmatic component features are considered and induce both stress and mass penalties. • A realistic tank design yields gravimetric efficiency of ≈37% and BOR ≈12 kg/h.