Integration of a novel hydrogen pressure vessel into small aircrafts

Abstract

Hydrogen is a promising alternative to fossil fuels in aviation, but its storage poses significant challenges, particularly in small aircraft/drones where space is limited. This study presents a novel approach to hydrogen storage by integrating load-bearing pressure vessels directly into aircraft wings. The design employs an innovative load introduction method adapted from composite tension–compression struts, enabling the manufacturing of elongated, small-diameter pressure tanks. This configuration optimises space utilisation whilst contributing to the structural integrity of the wing. Finite-element analysis (FEA) was conducted to evaluate the mechanical performance of the pressure vessels under aerodynamic loads. The results confirmed structural feasibility, but also indicated potential inter-fibre failure under cyclic loading. A prototype was manufactured and tested, pointing out some critical issues which needed further improvement. A refined design incorporating a preloaded metal dome (boss) successfully achieved a burst pressure exceeding 157.5 MPa, validating the concept. Future research will focus on optimising weight efficiency, investigating fatigue behaviour under long-term cyclic loading.