Open PhD position: Development of spin forming technology of cryogenic hydrogen tanks for world’s first zero emission commercial aircrafts

On September 21st 2020, Airbus revealed three concept designs of the world’s first zero-emission commercial aircraft whose estimated entry into service year is 2035. These game-changing concept aircraft, powered by hydrogen, will enable the integration of all required technologies. The business benefit is the decarbonisation of the aircraft industry.
Next steps are the maturation of all required hydrogen technologies by 2025 and the development of full-scale aircraft prototypes by the late 2020s.

In order to support Airbus ambition of bringing a zero-emission commercial aircraft to the market by 2035, this thesis will be an enabler to mature and manage the knowledge of Spin forming process on one specific aluminium alloy elementary part highlighted on the hydrogen tank design mockup. Nevertheless, it could also be an opportunity for other elementary parts, already in service. Spin forming is an incremental forming process for which the component to be formed is placed on a rotating mandrel and deformed iteratively by two rollers which reduces the component thickness. This process enables to produce lighter and stronger parts at a reasonable cost. However, due to the complexity of the process, the use of numerical simulation is mandatory and will be extensively developed and used in this project. Material characterization is also essential (behaviour and ductile damage) to produce parts of high quality.
This thesis will be part of one Corac [COnseil pour la Recherche Aéronautique Civile] project (governmental funding).

Main research axes are described below:
- Design rules definition in accordance with manufacturing drivers (Key Process Parameters). The PhD thesis will be supported by all stakeholders (French industrial company through a partnership and another Airbus supplier)
- Bibliographical study of the spinning process and on the influence of loading path on damage and fracture.
- Numerical modelling of the process and identification of the loading path. The Abaqus finite element software will be used.
- Material characterisation in terms of behavior law and ductile damage to prevent fracture.
- Design/Stress analysis (residual stresses, mechanical behavior, damage tolerance, S
- Limitations, capabilities (tolerances) for End to End process (assembly)
- Trials (correlation with Simulation). The PhD thesis will be supported by Airbus partners and Airbus suppliers.
- Analysis of Environmental footprint