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J. Compos. Sci.
Volume 9
Issue 9
10.3390/jcs9090480
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Article

Research on the Nonlinear Confined Buckling Pressure of a Thin-Walled Metal Liner with an Ovality Defect Installed Inside the Composite Overwrapped Pressure Vessels

by
Fuwei Gu
1,*,
Hu Xiao
1,
Hao Wang
1,
Zhiyang Chen
1,
Kang Su
1,
Zhiyi Tian
1,
Xinpeng Li
1 and
Yaguo Jin
2
1
School of Mechanical Engineering, Jiangsu University of Technology, Changzhou 213001, China
2
Jiangsu Ankura Intelligent Electric Co., Ltd., Changzhou 213001, China
*
Author to whom correspondence should be addressed.
J. Compos. Sci. 2025, 9(9), 480; https://doi.org/10.3390/jcs9090480
Submission received: 18 July 2025 / Revised: 14 August 2025 / Accepted: 26 August 2025 / Published: 3 September 2025
(This article belongs to the Section Composites Modelling and Characterization)
Versions Notes

Abstract

Composite overwrapped pressure vessels (COPVs) have become the core unit for high-pressure hydrogen storage and transportation. However, excessive autofrettage pressure could induce unilateral buckling damage of the metal liner because of large rebound compressive stress induced by large plastic deformation in the depressurization stage. When the liner contains initial defects, its critical unilateral buckling pressure would be further reduced. In this paper, a critical buckling pressure calculation formula was established by finite element analysis and theoretical derivation. Firstly, the classical theoretical calculation models and research methods were analyzed and discussed. Then, by discussing the key influencing parameters, a semi-empirical calculation formula of nonlinear confined buckling pressure of a metal liner with ovality defects was established. Finally, the proposed semi-empirical formula was used to predict the critical internal pressure of a Type-III COPV, and the predicted value was compared with the experimental result. The predicted result was higher than the experimental result and the error range was −2.8%~−23%. The proposed semi-empirical formula of nonlinear confined buckling could provide theoretical support for designing the autofrettage pressure of Type-III COPVs and help to reduce the uncertainty and repeated test cost in the design process.
Keywords: COPVs; thin-walled metal liner; nonlinear confined buckling; elastic buckling; ovality defect; finite element analysis COPVs; thin-walled metal liner; nonlinear confined buckling; elastic buckling; ovality defect; finite element analysis

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MDPI and ACS Style

Gu, F.; Xiao, H.; Wang, H.; Chen, Z.; Su, K.; Tian, Z.; Li, X.; Jin, Y. Research on the Nonlinear Confined Buckling Pressure of a Thin-Walled Metal Liner with an Ovality Defect Installed Inside the Composite Overwrapped Pressure Vessels. J. Compos. Sci. 2025, 9, 480. https://doi.org/10.3390/jcs9090480

AMA Style

Gu F, Xiao H, Wang H, Chen Z, Su K, Tian Z, Li X, Jin Y. Research on the Nonlinear Confined Buckling Pressure of a Thin-Walled Metal Liner with an Ovality Defect Installed Inside the Composite Overwrapped Pressure Vessels. Journal of Composites Science. 2025; 9(9):480. https://doi.org/10.3390/jcs9090480

Chicago/Turabian Style

Gu, Fuwei, Hu Xiao, Hao Wang, Zhiyang Chen, Kang Su, Zhiyi Tian, Xinpeng Li, and Yaguo Jin. 2025. "Research on the Nonlinear Confined Buckling Pressure of a Thin-Walled Metal Liner with an Ovality Defect Installed Inside the Composite Overwrapped Pressure Vessels" Journal of Composites Science 9, no. 9: 480. https://doi.org/10.3390/jcs9090480

APA Style

Gu, F., Xiao, H., Wang, H., Chen, Z., Su, K., Tian, Z., Li, X., & Jin, Y. (2025). Research on the Nonlinear Confined Buckling Pressure of a Thin-Walled Metal Liner with an Ovality Defect Installed Inside the Composite Overwrapped Pressure Vessels. Journal of Composites Science, 9(9), 480. https://doi.org/10.3390/jcs9090480

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