Acoustic emission characteristics of used 70 MPa type IV hydrogen storage tanks during hydrostatic burst tests

Currently, the periodic inspection of composite tanks is typically achieved via hydrostatic test combined with internal and external visual inspections. Acoustic emission (AE) technology demonstrates a promising nondestructive testing method for damage mode identification and damage assessment. This study focuses on AE signals characteristics and evolution behaviors for used 70 MPa Type IV hydrogen storage tanks during hydrostatic burst tests. AE-based tensile tests for epoxy resin specimen and carbon fiber tow were implemented to obtain characteristics of matrix cracking and fiber breakage. Then, broad-band AE sensors were used to capture AE signals during multi-step loading tests and hydrostatic burst tests. K-means ++ algorithm and wavelet packet transform are performed to cluster AE signals and verify the validity. Combining with tensile tests, three clusters are manifested via matrix cracking, fiber/matrix debonding and fiber breakage according to amplitude, duration, counts and absolute energy. The number of three clustering signals increases with the increase of pressure, showing accumulated and aggravated damage. The sudden appearance of a large number of fiber breakage signals during hydrostatic burst tests suggests that the composite tank structure is becoming mechanically unstable, namely the impending burst failure of the tank.     

Simulation and burst validation of 70 MPa type IV hydrogen storage vessel with dome reinforcement

The dome reinforcement (DR) technology was studied to reduce the amount of carbon fiber of the type IV hydrogen storage vessel in this paper. Firstly, the influence of the angle and thickness of the dome reinforcement part on the stress distribution of the dome section is studied by finite element analysis. Secondly, the weight reduction of carbon fiber composite layer is studied based on the dome reinforcement model. The strain-based Hashin progressive damage model is used to predict the burst pressure and burst mode with user-defined material subroutine (UMAT) of ABAQUS. Finally, the dome reinforcement technology is further verified in comparison with non-dome reinforcement by burst tests. The results show that the progressive damage model can effectively represent matrix cracking and fiber fracture, and the predicted burst pressure and mode is consistent with the test results. The fiber stress near the equator of the dome section affects the burst mode, and the smaller the angle of dome reinforcement parts, the better the reinforcing effect, and the dome reinforcement technology can help to improve the fiber damage state at the dome, transfer the maximum stress to the cylinder section of the vessel, and ensure the burst mode to be a safe mode. Also, it can help to reduce the consumption of carbon fiber by up to 5.5% in composite material.     

CFD analysis of fast filling scenarios for 70 MPa hydrogen type IV tanks

High injection pressure is combined with high refueling rate for vehicles storing pressurized gaseous hydrogen onboard. As a drawback, high temperatures are developed inside the tank, which can jeopardize the structural integrity of the storage system. Computational Fluid Dynamics (CFD) codes already proved to be a valuable tool for predicting the temperature distribution within the tank during fast refueling. Results of hydrogen fast filling CFD simulations for a type IV tank, filled to 70 MPa at different working conditions are presented as follow up of the CFD model validation performed against experimental data. Alternative rates of pressure rise, adiabatic and cold filling are investigated to evaluate the effect on maximum hydrogen temperatures inside the tank. Results confirmed that the developed CFD model could be a suitable tool for investigating fast filling scenarios when experimental data are not yet available or of difficult realization.     

Estimation of temperature change in practical hydrogen pressure tanks being filled at high pressures of 35 and 70 MPa

Some complete experimental data sets, not only on the hydrogen temperature within the tank during filling, but also on the supplied temperature and pressure from the station have been opened for analysis of the temperature change with time. The data were independently obtained for 6 different conditions and have been analyzed and checked to validate the Monde et al. model. It is found that the measured temperatures are well predicted using the software based on the model and the heat loss during filling with hydrogen is also well predicted, if a suitable heat transfer coefficient is adopted.     

Safety approach for composite pressure vessels for road transport of hydrogen. Part 1: Acceptable probability of failure and hydrogen mass

Hydrogen is a promising alternative for current energy carriers. Compressed gas cylinders are the storage systems closest to the commercialization of hydrogen in vehicles. The safety factors in current standards are seen as restrictive for further growth and competitiveness of hydrogen infrastructure. A probabilistic approach can be employed in order to give a rational background to the safety factors. However, an acceptable probability of failure needs to be estimated before calculating the safety factors. The discussion of determining the acceptable probability must include the mass of hydrogen since this determines the consequences of an accident. It is concluded that an annual probability of failure of 10⁻⁷ would be appropriate for small pressure vessels containing a few kilograms of hydrogen. Larger pressure vessels of a few hundred kilograms or more should be designed for an annual probability 10⁻⁸.     

Numerical study on fast filling of 70 MPa type III cylinder for hydrogen vehicle

There will be significant temperature rise within hydrogen vehicle cylinder during the fast filling process. The temperature rise should be controlled under the temperature limit (85 °C) of the structure material (set by ISO/TS 15869), because it may lead to the failure of the structure. In this paper, a 2-dimensional axisymmetric computational fluid dynamics (CFD) model for fast filling of 70 MPa hydrogen vehicle cylinder is presented. The numerical simulations are based on the modified standard k − ? turbulence model. In addition, both the equation of state for hydrogen gas and the thermodynamic properties are calculated by National Institute of Standards and Technology (NIST) database: REFPROP 7.0. The thermodynamic responses of fast filling with different pressure-rise patterns and filling times within type III cylinder have been analyzed in detail.     

Safety approach for composite pressure vessels for road transport of hydrogen. Part 2: Safety factors and test requirements

Composite pressure vessels for transporting hydrogen on roads are a promising and efficient solution for supplying refueling stations. The safety factors of current ISO design standards are perceived as being restrictive for design. In this paper, new safety factors are calculated based on a probabilistic approach and by extending the methods used in the DNV Offshore standard DNV-OS-C501 “Composite Components”. Short-term and long-term conditions are addressed.     

Evaluation of modeling techniques for a type III hydrogen pressure vessel (70 MPa) made of an aluminum liner and a thick carbon/epoxy composite for fuel cell vehicles

Stress distributions in the composite layers of a Type III hydrogen pressure vessel composed of a thin aluminum liner (5 mm) and a thick composite laminate (45 mm) were calculated by using three different modeling techniques. The results were analyzed and compared with the plausible stress distribution calculated by a full ply-based modeling technique. A laminate-based modeling technique underestimated the generated stresses especially at the border between the cylinder and dome parts. A hybrid modeling technique combining a laminate-based modeling for the dome part with a ply-based modeling for the cylinder part was also tried, but it overestimated the generated stresses at the border. In order for the ply-based modeling technique to carry out precise analysis, a fiber trajectory function for the dome part was derived and the composite thickness variation was also considered.