Periodic Reporting for period 3 - H2ELIOS (HydrogEn Lightweight & Innovative tank for zerO-emisSion aircraft)
Berichtszeitraum: 2024-01-01 bis 2024-12-31
To enable a technologically and economically feasible H2-powered aviation, new integral LH2 tank solutions are required that could serve as part of the airframe main structure and capable of withstanding its respective loads.
The H2ELIOS project will develop an innovative and effective lightweight LH2 storage system for aircraft. It will be implemented as demonstrators in two fuselage-like cylinder section with approximately 1.9 m of external diameter and approximately 2.3 m of external length. These demonstrators would be duly supported by component and subsystem ground tests at appropriate scale at project completion (TRL 5 at storage level). The aim is that the concept is ready to be embedded and integrated in a specified aircraft architecture for flight demonstration in later stages.
H2ELIOS will provide a feasible and novel low-pressure double-layer composite tank-based system, enabling the tank shape to be either conformal or non-conformal to the profile of the aircraft. Its general effectiveness will be assessed in terms of high GI performance and easiness of integration within the aircraft structure.
This concept will be supported by latest evolutions of innovative methods and technologies in terms of multidisciplinary design development, manufacturing processes and means of compliance and shall be demonstrated in operational conditions: first on ground up to TRL5 and then in flight by the end of Clean Aviation Phase 2 clearing a TRL6 maturation gate. Finally, delivery to the market is expected in the 2030-2035 period. In this way this project shall contribute to accomplish the objectives of the European Green Deal regarding decarbonization of the aviation industry.
The activities of H2ELIOS will be supported by explicit agreed support of EASA and an External Advisory Board comprising commercial aircraft OEMs, H2 management and cryogenics experts, MRO services, airlines, aircraft system integrators, materials developers and suppliers and airports operation.
The H2ELIOS project will develop an innovative and effective lightweight LH2 storage system for aircraft. It will be implemented as demonstrators in two fuselage-like cylinder section with approximately 1.9 m of external diameter and approximately 2.3 m of external length. These demonstrators would be duly supported by component and subsystem ground tests at appropriate scale at project completion (TRL 5 at storage level). The aim is that the concept is ready to be embedded and integrated in a specified aircraft architecture for flight demonstration in later stages.
H2ELIOS will provide a feasible and novel low-pressure double-layer composite tank-based system, enabling the tank shape to be either conformal or non-conformal to the profile of the aircraft. Its general effectiveness will be assessed in terms of high GI performance and easiness of integration within the aircraft structure.
This concept will be supported by latest evolutions of innovative methods and technologies in terms of multidisciplinary design development, manufacturing processes and means of compliance and shall be demonstrated in operational conditions: first on ground up to TRL5 and then in flight by the end of Clean Aviation Phase 2 clearing a TRL6 maturation gate. Finally, delivery to the market is expected in the 2030-2035 period. In this way this project shall contribute to accomplish the objectives of the European Green Deal regarding decarbonization of the aviation industry.
The activities of H2ELIOS will be supported by explicit agreed support of EASA and an External Advisory Board comprising commercial aircraft OEMs, H2 management and cryogenics experts, MRO services, airlines, aircraft system integrators, materials developers and suppliers and airports operation.
Within the first 6 months of activity major activity has focused in:
- Issue an iteration of requirements and specification deliverables regarding LH2 storage function on an a/c and LH2 storage integral demonstrator respectively. Additionally, also a first analysis of the airworthiness CS25 code was performed to identify gaps and needs of modification
- Kick-off of activities with EASA in order to review requirements (in particular the ones related airworthiness)
- Definition and execution of initial stages of materials coupon testing, including the manufacturing of those coupons which implied also the first stages in the definition of the manufacturing process to be applied in the demonstrator
- Issue of several documentation regarding project management and coordination with other Clean Aviation projects covering: dissemination, communication, exploitation and IP management; internal project management procedures, gender action plan and cooperation plan
- FDR phase of the demonstrator was started and major areas of focus were prioritised in order to optimice resource use.
In the second 6 months of activity (from month 7 to month 12 of the project) activities and main achievements were the following:
- Important progress was made in the manufacturing technologies area. Both composite manufacturing technologies, for outer and inner tank of the LH2 storage demonstrators, produced further coupons to evaluate/confirm material characteristics. Additionally, for the inner tank in which additive manufacturing technology would be used, several larger size manufacturing trials were also executed. This validated the scalability potential of the technology as well as contributed to further mature and set-up the process parameters.
- The primary functions of the LH2 storage system were defined. A subsystem architecture was meticulously designed and represented in a fluids architecture diagram to effectively address those functions. In addition, vital parameters were established based on the Key Performance Indicators (KPIs) of the tank. Parameters that need to be monitored or controlled during operations were also identified, and corresponding sensors were integrated into the architecture.
- Interaction with EASA was reinforced and several workshops organised in which safety related technical aspects of the H2ELIOS LH2 storage concept were discussed. Important leanings have been gathered and applied to the project, triggering relevant decisions regarding a/c integration approach.
In 2024 H2ELIOS project went through a major phase of progress in which:
- The Preliminary Design Review of the demonstrator was performed with a very relevant participation of representatives of linked projects and other stakeholders, being specially relevant the active presence of EASA. Very important feedback was received which triggered specific actions that were closed within 2024 enabling a clear path towards Critical Design Review.
- Demonstrator definition progressed accordingly reaching a pre-CDR status by the end of the year. Outputs from this progress relevant for the impact monitoring activity, and in particular for the eventual products that could be based on the hydrogen storage technology escalated to use cases being developed in other Clean Aviation projects. H2ELIOS configuration show a very promising performance when extrapolated to a product; this is very remarkable as these figures are above targets identified for the associated aircraft configuration within Clean Aviation, and in H2ELIOS project considerations of crashworthiness and safety aspects are being taken into account which imply specific design features contributing to weight.
- Strong campaign of coupon tests were completed and relevant progress was achieved in component level testing. Very important activity was done in the field of insulation performance tests.
- Manufacturing and assembly tooling were cleared for final design and manufacturing in some cases within the year.
- Issue an iteration of requirements and specification deliverables regarding LH2 storage function on an a/c and LH2 storage integral demonstrator respectively. Additionally, also a first analysis of the airworthiness CS25 code was performed to identify gaps and needs of modification
- Kick-off of activities with EASA in order to review requirements (in particular the ones related airworthiness)
- Definition and execution of initial stages of materials coupon testing, including the manufacturing of those coupons which implied also the first stages in the definition of the manufacturing process to be applied in the demonstrator
- Issue of several documentation regarding project management and coordination with other Clean Aviation projects covering: dissemination, communication, exploitation and IP management; internal project management procedures, gender action plan and cooperation plan
- FDR phase of the demonstrator was started and major areas of focus were prioritised in order to optimice resource use.
In the second 6 months of activity (from month 7 to month 12 of the project) activities and main achievements were the following:
- Important progress was made in the manufacturing technologies area. Both composite manufacturing technologies, for outer and inner tank of the LH2 storage demonstrators, produced further coupons to evaluate/confirm material characteristics. Additionally, for the inner tank in which additive manufacturing technology would be used, several larger size manufacturing trials were also executed. This validated the scalability potential of the technology as well as contributed to further mature and set-up the process parameters.
- The primary functions of the LH2 storage system were defined. A subsystem architecture was meticulously designed and represented in a fluids architecture diagram to effectively address those functions. In addition, vital parameters were established based on the Key Performance Indicators (KPIs) of the tank. Parameters that need to be monitored or controlled during operations were also identified, and corresponding sensors were integrated into the architecture.
- Interaction with EASA was reinforced and several workshops organised in which safety related technical aspects of the H2ELIOS LH2 storage concept were discussed. Important leanings have been gathered and applied to the project, triggering relevant decisions regarding a/c integration approach.
In 2024 H2ELIOS project went through a major phase of progress in which:
- The Preliminary Design Review of the demonstrator was performed with a very relevant participation of representatives of linked projects and other stakeholders, being specially relevant the active presence of EASA. Very important feedback was received which triggered specific actions that were closed within 2024 enabling a clear path towards Critical Design Review.
- Demonstrator definition progressed accordingly reaching a pre-CDR status by the end of the year. Outputs from this progress relevant for the impact monitoring activity, and in particular for the eventual products that could be based on the hydrogen storage technology escalated to use cases being developed in other Clean Aviation projects. H2ELIOS configuration show a very promising performance when extrapolated to a product; this is very remarkable as these figures are above targets identified for the associated aircraft configuration within Clean Aviation, and in H2ELIOS project considerations of crashworthiness and safety aspects are being taken into account which imply specific design features contributing to weight.
- Strong campaign of coupon tests were completed and relevant progress was achieved in component level testing. Very important activity was done in the field of insulation performance tests.
- Manufacturing and assembly tooling were cleared for final design and manufacturing in some cases within the year.
Currently there are no actual impacts generated in the project. However, at proposal stage were identified areas of impact of the project and during 2023 Q2 were started activities within Tasks 6.3 and 6.4 focused in the track record of the expected Key Exploitable Results, IPR management and agreement within H2ELIOS consortium and the establishment of an initial Cooperation Plan with other relevant Clean Aviation projects that would contribute to achieve H2ELIOS performance in both technical and impact aspects.