Integrating Computer-Aided Design and Model-Based Systems Engineering for Early Zonal Hazard Analysis: Application to a Supersonic Aircraft Fuel System

The development of supersonic aircraft presents significant challenges in ensuring safety during early design stages, particularly for fuel tank systems exposed to extreme thermal and structural loads. Conventional document-based zonal safety analysis methods are limited in their ability to capture dynamic interactions between spatial subsystem configurations and functional system behavior during early conceptual design, leading to delayed hazard identification. This study proposes an integrated framework combining computer-aided design (CAD) and model-based systems engineering (MBSE) to support early-stage zonal hazard analysis. The framework links spatial subsystem modelling with functional system architecture to enable iterative hazard identification and mitigation. Applied to the SA-24 Phoenix conceptual supersonic aircraft, the approach identifies critical risks, including fuel vaporization, over-pressurization, and structural fatigue, and evaluates mitigation strategies such as thermal insulation and redundant venting. Functional hazard analysis and fault tree analysis are used to assess failure scenarios and ensure compliance with EASA CS-25 requirements. Results indicate an estimated reduction of up to 40% in risk priority number (RPN) values for key thermal hazard pathways and a 25% reduction in conceptual design iteration time compared with conventional approaches. The findings demonstrate that CAD–MBSE integration offers a scalable and efficient methodology for early hazard identification, contributing to safer and more reliable supersonic aircraft design.