Airbus readies for maiden flight test of hydrogen fuel-cell engine of megawatt class
Airbus is making significant strides in the development of hydrogen-powered fuel cell engines as part of its ZEROe program, aiming to create a sustainable aviation future.
Internal Production and Key Components
The European aerospace giant is producing the distribution center and motor controller unit for the hydrogen fuel-cell engine demonstrator internally. Airbus Helicopters and Defence and Space colleagues are also developing the propelling system and the gearbox associated with the pitch control for the demonstrator.
Fuel Cell Operation
The gaseous hydrogen from the cryogenic tank is distributed to the fuel cell via supply lines, an external 'stub' aerodynamic and load-bearing support structure, and the engine pylon interface. Dioxygen (O2) molecules are supplied by a controlled flow of air taken from the surrounding atmosphere within the fuel cell. The resulting reaction inside the fuel cell produces direct electrical current (DC), which is subsequently converted into alternating current (AC) by the means of inverters.
Powering the Propulsion
These fuel cells power electric motors, which convert electrical power into mechanical power to drive the propeller for thrust. Water is produced as a byproduct of the electrochemical reaction and is expelled from an outlet at the back of the pod.
Testing and Integration
The A380 MSN001 will be retrofitted with hydrogen fuel cell engines to conduct flight tests, serving as a flying testbed for ZEROe technologies. By 2026, the teams aim to test the entire system in the integrated test bench (ITB), which will be built in 2024 and connected to the same flight test instrumentation as for the A380 MSN001.
Cryogenic Storage and Cooling
A 10m long, 4m wide housing made of carbon fiber, referred to as the "tent", will be crafted by Airbus Atlantic team at the Technocentre de Nantes to house up to four cryogenic tanks containing liquid hydrogen. The thermal energy generated by the fuel cell needs to be conveyed by a liquid cooling system to heat exchangers where it is dissipated into the ambient air.
Ground Testing Activities
Extensive ground testing activities are underway, including electrical benches, thermal management systems, and several fuel-cell integration benches. Emergency venting lines have been incorporated to expel hydrogen out of the emergency line if needed, ensuring safety inside the A380. From 2024, additional integrated test benches such as a fuel cell system integration bench, a functional integration bench, and a Propeller Integration Bench will be added.
Partnership and Collaboration
Airbus has been collaborating with partners like MTU Aero Engines, who signed a cooperation agreement with Airbus in mid-2025 to accelerate this critical technology for aviation decarbonization. The hydrogen-powered fuel-cell engine architecture with cryogenic storage is a key component of the world's first zero-emission commercial airliner, which could enter service by 2035.
The Future of Zero-Emission Aviation
The fourth ZEROe concept aircraft features six eight-bladed propellers attached to engine pods, which contain hydrogen fuel cells that produce electricity through an electro-chemical reaction. This step is essential for validating the technology’s performance, safety, and integration challenges before commercial deployment. Airbus aims to demonstrate zero-emission flight with these fuel cells in the near future as part of its ZEROe strategy, targeting a commercial hydrogen aircraft by 2040–2045.
