Sloshing-Induced Thermo-Hydrodynamic Characteristics of Onboard Liquid Hydrogen Cylinders: Effects of Filling Ratio

The safety and stability of onboard Liquid Hydrogen (LH2) storage systems depend strongly on gas–liquid two-phase flow, heat transfer, and phase change under sloshing; however, the coupled influence of filling ratio and sloshing on thermo-hydrodynamic behavior remains underexplored. We develop a Volume of Fluid (VOF)-based two-phase Computational Fluid Dynamics (CFD) model in ANSYS Fluent to quantify interfacial dynamics, pressure response, and temperature-field evolution in LH2 tanks subjected to sinusoidal acceleration for filling ratios from 10% to 90%. Increasing the filling ratio strengthens net condensation in the ullage and thus intensifies depressurization. As the filling ratio increases from 10% to 90%, the pressure reduction over the 2.0 s sloshing process increases from 0.418 kPa to 2.410 kPa, and the corresponding initial depressurization rate rises from 0.209 to 1.205 kPa s−1. Free-surface motion decreases with filling ratio: at 10%, large interface excursions can induce gas-cavity formation and splashing, increasing the risk of intermittent propellant supply, whereas at 90% the interface is constrained and oscillations are suppressed. Higher filling ratios lead to faster ullage cooling and larger temperature oscillations. The liquid warms modestly, and its warming rate decreases nonlinearly with filling ratio, consistent with the larger effective thermal mass at higher fillings. Overall, the obtained mechanistic understanding can support the engineering design of onboard LH2 tanks, including filling-ratio selection and thermal-management optimization under sloshing conditions.