Design Optimization and Structural Evaluation of a Fully Composite Type V Hydrogen Tank for Use in Aviation

AIAA SCITECH 2026 Forum, Florida, Amerika Birleşik Devletleri, 12 - 16 Ocak 2026, ss.1-8, (Tam Metin Bildiri)

The growing demand for sustainable energy solutions in the aerospace industry, particularly

in line with the Paris Agreement, has accelerated interest in hydrogen-based onboard fuel

systems. This study focuses on the optimization and structural analysis of a lightweight and

high-strength Type V composite pressure vessel designed for aviation applications and capable

of storing gaseous hydrogen at an internal pressure of 700 bar.A filament-wound manufacturing

approach was selected due to its favorable strength-to-weight characteristics. The optimization

process was conducted using an integrated computational framework developed in MATLAB

and ANSYS ACP, and a two-stage methodology was adopted. In the first stage, a prototype

was manufactured based on initial optimization results, and a leakage test was performed.

The test outcomes revealed certain deviations between the measured response and simulation

predictions. These findings were then utilized as key inputs in the second stage, where the

design space was redefined, a refined optimization study was conducted, and the fabrication

of a second prototype was initiated. In both stages, Genetic Algorithms (GA) coupled with

surrogate models were employed to efficiently explore the design space. Structural assessments

were carried out using finite element analysis (FEA), incorporating the failure criterias to

examine the mechanical integrity of the tank. This study aims to contribute to the development

of high-performance and lightweight hydrogen storage solutions aligned with the sustainability

objectives of the aerospace sector by presenting a systematic engineering approach that integrates

manufacturing–testing–re-optimization cycles.