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Design Optimization and Analysis of Long-Range Hydrogen-Fuelled Hypersonic Cruise Vehicles

par Sharifzadeh, Shayan
Président du jury Degrez, Gérard
Promoteur Hendrick, Patrick ;Verstraete, Dries
Co-Promoteur Vio, Gareth
Publication Non publié, 2017-08-25

Thèse de doctorat

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Résumé :

Aviation industry is continuously growing especially for very long distance flights due to the globalisation of local economies around the world and the explosive economic growth in Asia. Reducing the time of intercontinental flights from 16-20 hours to 4 hours or less would therefore make the, already booming, ultra-long distance aviation sector even more attractive. To accomplish this drastic travel time reduction for civil transport, hypersonic cruise aircraft are considered as a potential cost-effective solution. Such vehicles should also be fuelled by liquid hydrogen, which is identified as the only viable propellant to achieve antipodal hypersonic flight with low environmental impact. Despite considerable research on hypersonic aircraft and hydrogen fuel, several major challenges should still be addressed before such airliner becomes reality. The current thesis is therefore motivated by the potential benefit of hydrogen-fuelled hypersonic cruise vehicles associated with their limited state-of-the-art.Hypersonic cruise aircraft require innovative structural configurations and thermal management solutions due to the extremely harsh flight environment, while the uncommon physical properties of liquid hydrogen, combined with high and long-term heat fluxes, introduce complex design and technological storage issues. Achieving hypersonic cruise vehicles is also complicated by the multidisciplinary nature of their design. In the scope of the present research, appropriate methodologies are developed to assess, design and optimize the thermo-structural model and the cryogenic fuel tanks of long-range hydrogen-fuelled hypersonic civil aircraft. Two notional vehicles, cruising at Mach 5 and Mach 8, are then investigated with the implemented methodologies. The design analysis of light yet highly insulated liquid hydrogen tanks for hypersonic cruise vehicles indicates an optimal gravimetric efficiency of 70-75% depending on insulation system, tank wall material, tank diameter, and flight profile. A combination of foam and load-bearing aerogel blanket leads to the lightest cryogenic tank for both the Mach 5 and the Mach 8 aircraft. If the aerogel blanket cannot be strengthened sufficiently so that it can bear the full load, then a combination of foam and fibrous insulation materials gives the best solution for both vehicles. The aero-thermal and structural design analysis of the Mach 5 cruiser shows that the lightest hot-structure is a titanium alloy construction made of honeycomb sandwich panels. This concept leads to a wing-body weight of 143.9 t, of which 36% accounts for the wing, 32% for the fuselage, and 32% for the cryogenic tanks. As expected, hypersonic thermal loads lead to important weight penalties (of more than 35%). The design of the insulated cold structure, however, demonstrates that the long-term high-speed flight of the airliner requires a substantial thermal protection system, such that the best configuration (obtained by load-bearing aerogel blanket) leads to a titanium cold design of only 4% lighter than the hot structure. Using aluminium 7075 rather than titanium offers a further weight saving of about 2%, resulting in a 135.4 t wing-body weight (with a contribution of 23%, 25%, 18% and 34% from the TPS, the wing, the fuselage, and the cryogenic tanks respectively). Given the design hypotheses, the difference in weight is not significant enough to make a decisive choice between hot and cold concepts. This requires the current methodologies to be further elaborated by relaxing the simplifications. Investigation of the thermal protection must be extended from one single point to different regions of the vehicle, and the TPS thickness and weight should be considered in the structural sizing of the cold design. More generally, the design process should be matured by including additional (static, dynamic and transient) loads, special structural concepts, multi-material configurations and other parameters such as cost and safety aspects.