On the use of lattice structures produced through Additive Manufacturing for multifunctional and efficient Thermal Management of aircraft fuel tanks

This thesis focuses on the thermal optimization of an aircraft fuel tank, aiming to transform it from a passive storage component into an active contributor to the aircraft’s Thermal Management System. Traditionally, fuel tanks act as classical storage, where fuel is used as a coolant in heat exchange systems. The goal of this research is to redesign the tank's geometry to actively dissipate heat, making the tank a more effective part of the aircraft’s overall thermal regulation. This project runs parallel to another study focused on the structural optimization of the aircraft’s wing and fuel tank. While this thesis concentrates on thermal performance, the other project addresses weight reduction and material distribution using topological optimization. This method removes material from areas of low stress while reinforcing regions that require greater strength. Together, these efforts will result in an integrated component that maximizes both cooling efficiency and structural robustness. One of the most significant aspects of this research is the use of Additive Manufacturing makes it possible to integrate multiple functionalities, such as heat dissipation and structural support, within a single component, reducing the total number of parts and simplifying assembly processes. This study proposes redesigning the fuel tank as an active heat exchanger, improving the cooling process during fuel storage. This redesign will increase the fuel’s ability to absorb heat in the next cycle, reducing the need for additional active cooling systems. This approach provides two main benefits. First, it reduces the overall weight of the aircraft by eliminating the need for extra cooling components, which increases fuel efficiency. A lighter aircraft consumes less fuel, leading to lower emissions and operational costs. Second, the integration of thermal and structural optimization, offers significant potential for improving the performance and competitiveness of modern aircraft. This work also addresses several critical challenges. Another challenge involves optimizing the tank’s geometry to maximize surface area for heat exchange, often requiring complex shapes that are not easily achieved with traditional methods. The findings of this research are expected to provide innovative design solutions for not only fuel tanks but also other critical aerospace components. By integrating thermal and structural optimization in a single component, this study paves the way for enhancing the efficiency and functionality of future aircraft designs.