Session: 03-11 Sustainable Aviation Fuels (SAF), Biofuels, and Fuel Flexibility

Submission Number: 178382

Design and Analysis of Hexagonal Honeycomb Layers for Thermal-Structural Performance in Ammonia Fuel Tanks 

The decarbonization of aviation requires the development of advanced fuel storage systems capable of safely and efficiently containing alternative fuels such as liquid ammonia. This research study presents a design and analysis study of honeycomb layers integrated within dual-walled, vacuum-insulated fuel tanks to enhance both thermal insulation and structural reinforcement. The hexagonal honeycomb layer serves a dual role: providing mechanical stability to withstand operational loads and pressure differentials, while simultaneously reducing conductive heat transfer across the vacuum gap, thereby minimizing boil-off losses. Computational fluid dynamics and finite element analysis simulations are conducted to evaluate thermal-structural performance under representative loading and temperature conditions for mid-sized commercial aircraft, with emphasis on the Boeing 737 MAX-8 center wing tank geometry. Parametric variations in honeycomb cell size, wall thickness, and pitch-to-thickness ratios are explored to identify optimal configurations balancing strength-to-weight efficiency with reduced effective thermal conductivity. Candidate materials including glass-fiber phenolic composites, stainless steel, and carbon-fiber honeycomb are assessed for compatibility with ammonia-powered flight operation. Carbon fiber honeycombs demonstrate superior strength to weight ratios in preliminary tests, though glass fiber composites prove greater compatibility with ammonia’s toxic nature and offer cost savings in manufacturability. Results demonstrate that properly optimized honeycomb layers can significantly reduce thermal leakage while maintaining robust structural performance, supporting the feasibility of ammonia fuel tanks as enablers for sustainable aviation.

Presenting Author: Ethan Taylor University of Central Florida

Presenting Author Biography: Ethan Taylor:

Current Role: Graduate Research Assistant, Aerospace Engineering, University of Central Florida (CATER Lab / NASA ULI)

Education: B.S. Mechanical Engineering, UCF (Dec 2024); M.S. Aerospace Engineering (Jan 2025 - Present, UCF); Ph.D. Aerospace Engineering (Jan 2025 - Present, UCF)

Research Focus: Thermal–structural design and airframe integration of cryogenic ammonia fuel storage and delivery for narrow-body aircraft, including insulation architectures, tank–airframe interfaces, and coupled heat-transfer/FEA/CFD modeling.

Authors:

Ethan Taylor University of Central Florida
Kangana Patel University of Central Florida
Mairah Ahmed University of Central Florida
Rohan Jay University of Central Florida
Shinjan Ghosh University of Central Florida
Marcel Otto University of Central Florida
Erik Fernandez University of Central Florida
Jayanta Kapat University of Central Florida