- Can you briefly describe your role within the COCOLIH₂T project and the main focus of your Work Package?
My role within COCOLIH2T is the work package lead for Work Package 3 – Design and Manufacture. This role involves working with and coordinating the various members within the work package as well as assisting and providing technical support.
WP3 is centred on several topics which included the selection and assessment of appropriate composite materials in terms of containing cryogenic hydrogen, the general arrangement and design concept of the multiwalled tank design and associated features to best fit the project requirements, the design of the composite structures themselves, and developing the advanced manufacturing methods to make these structures. Each topic has significant influence on others in terms of capability, viability and performance and the influence of each decision made on others must be considered at each stage.
- What has been one of the most interesting or unexpected challenges so far, and how did you and/or your team address it?
Matching the manufacturing capabilities to the design and performance requirements was a significant challenge. This was evident not only as part of the design and manufacturing work-package, but also how the demonstrators would impact the needs of all other work packages. Continued communication was therefore necessary, not only within WP3 but also the entire COCOLIH2T team. Of particular importance was working with other work packages developing items that would physically interact with the tanks produced. An example of an approach to address this necessity was the inclusion of flat, metallic interface plates used to allow items such as pipework or sensors etc to pass through otherwise sealed tank walls through a known and agreed interface. Although the introduction of these interface plates did create their own challenges these did allow multiple technologies across various work packages to be developed in parallel and still be included as part of the final assembly.
Focusing more specifically within WP3, developing designs that allowed the carbon fibre composite material to be orientated in an effective and efficient manner over such a large and complex structure using the manufacturing techniques available required considerable thought, simulations, and multiple iterations. In addition, the development and manufacture of a multipiece removable mould that could be used with the automated fibre placement (AFP) process as well as other processing requirements was an interesting challenge. As part of including such a necessary manufacturing tool, the tank design also had to allow for such a mould to be successfully removed.
- What key lessons or insights have you gained from working on COCOLIH₂T?
The COCOLIH2T project highlights that to develop projects which include investigations and advancements in multiple complex fields such as materials, advanced manufacturing methods, sensors, cryogenic fluid management and containment, as well as introducing new technologies into the aviation sector requires not only multi-skilled teams but the means to bring all these aspects together into a working system. COCOLIH2T provided an excellent opportunity for close collaboration with industrial and academic partners to jointly develop new technologies. Regular and open communication helped throughout the entire project lifecycle.
- Looking ahead, how do you see this project influencing future research or industry practices?
COCOLIH2T not only highlighted the requirements and challenges assotiated with cryogenic fuel storage in aviation but also the requirement to have good understanding in the underlying technologies required to develop such a project. This is obviously the case for any complex and multifaceted engineering development. In such projects, when you reflect on what worked well and what aspects had challenges this helps inform the direction of travel for future developments. It also highlights the benefit for investment in effort for a strong multi-level TRL process and ‘building bock’ approach which includes these underlying technologies to form the most effective system solutions.
- If you were to describe the COCOLIH₂T project in three words, what would they be — and why?
Synergistic – The multiple requirements of various physical and none-physical aspects of the programme need to work together to be effective.
Challenging – The development of a complex system that is reliant on the bringing together of low-maturity technologies and having to solve previously unidentified requirements as the project developed and the system needs became more apparent, provided continuous challenges.
Fun – COCOLIH2T was not only a great chance to explore technologies, methods, and problems that may not usually be accessible, but it also provided an excellent opportunity to meet great and very talented people across the entire COCOLIH2T team. It was a real pleasure to meet and get to know all team members, both in terms of the technical side within the project as well as some great social events that resulted from working together!