Structural Assessment of a Compact Offset Strip Fin Heat Exchanger for Hydrogen Fuel Cell Electric Aircraft ^†

Hydrogen fuel cells offer strong potential for decarbonizing aviation, yet their megawatt-scale integration is limited by thermal management system (TMS) challenges. In low-temperature Proton Exchange Membrane Fuel Cell (PEMFC) systems, the heat exchanger (HEX) is the key TMS component influencing thermal efficiency, mass, and reliability. While prior work has focused on thermo-hydraulic optimization, structural behavior under flight conditions remains insufficiently addressed. This study introduces a coupled CFD–FEA methodology for a nacelle-integrated, megawatt-class plate–fin HEX. The model captures the effects of non-uniform thermal loads, constrained thermal expansion, and dynamic excitation. Local flow-induced vibrations are assessed through pre-stressed modal analysis, and global dynamic behavior is predicted using a homogenized approach. Results show that thermally induced stresses dominate over pressure loads, and the introduction of coolant-fin geometries with suitable expansion tolerances mitigates stress and resonance risks. The approach provides design guidance for structurally robust, vibration-tolerant, and aero-thermally efficient HEXs for next-generation PEMFC-powered aircraft.