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Article

A Modeling Approach for Assessing Vibration Immunity in Hydrogen Fuel Cell Stack for Aeronautical Applications

by
Giovanni Fasulo
1,*,
Simone Gallas
2,3,
Hervé Denayer
2,3,
Oskar Ekblad
4,
Giancarlo Kosova
5 and
Mattia Barbarino
1
1
Italian Aerospace Research Centre (CIRA), 81043 Capua, Italy
2
Department of Mechanical Engineering, KU Leuven, 3001 Heverlee, Belgium
3
Flanders Make, Flanders Make@KU Leuven, 3001 Heverlee, Belgium
4
PowerCell Group, SE-418 34 Gothenburg, Sweden
5
Siemens Digital Industries Software, 3001 Leuven, Belgium
*
Author to whom correspondence should be addressed.
Appl. Sci. 2026, 16(1), 69; https://doi.org/10.3390/app16010069 (registering DOI)
Submission received: 17 November 2025 / Revised: 11 December 2025 / Accepted: 15 December 2025 / Published: 20 December 2025
(This article belongs to the Special Issue Advances in Aerostructural Analysis, Design, and Optimization)

Abstract

Fuel cells offer a promising route to eliminating in-flight emissions from regional aviation, but certification requires proof that stacks can withstand the vibration and shock environment of turboprop aircraft. As part of the EU-funded NEWBORN project, we combined detailed finite element modeling with shaker tests to evaluate the vibration immunity of PowerCell Group’s prototype stack. The numerical model combined an orthotropic, two-zone 3D mesh of the cell package with reduced-order representations of plates, compression bands, disc springs and the mounting cage. The assembled stack was excited between 10 and 300 Hz using pseudo-random and sine-sweep inputs up to 2.0 g, from which 54 frequency response functions were obtained. The tuned model accurately reproduced the first global modes and captured the overall dynamic behavior with good, though not perfect, agreement. The combined numerical–experimental methodology therefore offers a framework for refining test campaigns and delivering early, qualitative evidence of vibration immunity in fuel cell stacks destined for flight.
Keywords: fuel cells; finite element modeling; modal analysis; vibration testing; RTCA/DO-160G; turboprop aircraft; sustainable aviation fuel cells; finite element modeling; modal analysis; vibration testing; RTCA/DO-160G; turboprop aircraft; sustainable aviation

Share and Cite

MDPI and ACS Style

Fasulo, G.; Gallas, S.; Denayer, H.; Ekblad, O.; Kosova, G.; Barbarino, M. A Modeling Approach for Assessing Vibration Immunity in Hydrogen Fuel Cell Stack for Aeronautical Applications. Appl. Sci. 2026, 16, 69. https://doi.org/10.3390/app16010069

AMA Style

Fasulo G, Gallas S, Denayer H, Ekblad O, Kosova G, Barbarino M. A Modeling Approach for Assessing Vibration Immunity in Hydrogen Fuel Cell Stack for Aeronautical Applications. Applied Sciences. 2026; 16(1):69. https://doi.org/10.3390/app16010069

Chicago/Turabian Style

Fasulo, Giovanni, Simone Gallas, Hervé Denayer, Oskar Ekblad, Giancarlo Kosova, and Mattia Barbarino. 2026. "A Modeling Approach for Assessing Vibration Immunity in Hydrogen Fuel Cell Stack for Aeronautical Applications" Applied Sciences 16, no. 1: 69. https://doi.org/10.3390/app16010069

APA Style

Fasulo, G., Gallas, S., Denayer, H., Ekblad, O., Kosova, G., & Barbarino, M. (2026). A Modeling Approach for Assessing Vibration Immunity in Hydrogen Fuel Cell Stack for Aeronautical Applications. Applied Sciences, 16(1), 69. https://doi.org/10.3390/app16010069

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