TEST

Airbus is committed to leading the decarbonisation of the aerospace industry. Our strategy is a multi-faceted approach with one of the pathways focused on achieving the technological maturity required to bring more sustainable and efficient aircraft to market. This includes boosting manufacturing rate, implementing advanced capabilities, and achieving significant recurring cost reductions. The result is increased customer value through lower fuel consumption, reduced CO2 emissions, and optimized operational costs.

The TEST project is crucial, laying the groundwork for Airbus' ambitious emissions reduction roadmap. Its core focus is the research, design, and development of two advanced cooling systems (Primary and Secondary modules) essential for managing the high heat dissipation generated by Hydrogen Fuel Cells within a future aerial demonstrator.

One of the major technical challenges in fuel cell systems is the considerable amount of heat generated that requires management. Therefore, TEST aims to design and integrate a complete cooling system based on two modules:

• Primary Module (Front): A cooling system featuring an Air-Liquid Heat Exchanger, with a movable surface at the outlet for flow control and a protective Firewall.
• Secondary Module (Rear): Multiple Heat Exchangers and fans, equipped with movable surfaces at both the inlet and outlet for precise temperature control.

To this end, innovative thermal management technologies will be investigated to surpass the current state-of-the-art. These technologies will be implemented within a comprehensive electric propulsion system, addressing the integration and flight challenges. As a result, a safe thermal management system will be tested to serve the fuel cell, integrating into a complete propulsion system—an achievement never before realised in Spain.

We are actively developing the next generation of aircraft, and our TEST project is contributing with the manufacturing of the technological thermal management system of the hydrogen aircraft.

The challenge is significant, as fuel cells generate an important amount of heat. We are tackling this by designing an Advanced Thermal Management System that provides cooling to guarantee optimal flight performance.

To ensure this technology remains viable in the air, we have developed Structural Reliability architectures that completely isolate the most sensitive components, such as our large Heat Exchangers, from extreme engine vibrations.

In parallel, we are pioneering Novel System Integration by safely incorporating and managing High-Voltage cables (DC and AC) within the aircraft. This is a completely new requirement at our Getafe center that involves developing advanced protection against sparks and electromagnetic interference for total safety.

Finally, we ensure Manufacturing Optimisation for the future aircraft through innovative processes like 'OneShot' and new composite materials. This allows us to build complex, lightweight, and resilient parts more efficiently and at a lower cost, positioning AIRBUS Spain as an undisputed leader in the sustainable aviation value chain.

Please note that the technical details and scope described on this page reflect the activities of the TEST project as submitted in 2024.
 

The AIRBUS TEST project plays a leading role in aerospace decarbonisation, focused on overcoming the most critical technological challenges for hydrogen propulsion. The goal is to develop and validate the thermal and structural management systems that will enable the manufacturing of the first zero-emission commercial aircraft.

Our innovation centers on four key value pillars:

The TEST project not only validates a technology but positions AIRBUS as a leader in the sustainable aviation value chain.