Search Results (13)

A 70 MPa Type IV hydrogen composite pressure vessel (CPV) was instrumented with embedded Fiber Bragg Grating (FBG) sensors to realize in situ strain monitoring during hydraulic fatigue cycles. FBG arrays were co-wound with carbon fibers during the filament winding process, forming an integrated multi-point sensing network within the composite layers. Hydraulic fatigue tests were conducted under pressure cycling between 2 MPa and 87.5 MPa, reaching 48,000 cycles. The embedded FBG sensors were able to stably record cyclic strain evolution with peak amplitudes of approximately 6000 με in the hoop layer and 3500 με in the helical layer under hydraulic cycling. The hoop layers exhibited gradually decreasing strain amplitudes from the inner to outer regions, while the helical layer maintained stable signal performance. Analysis of fiber survival times indicated that the FBGs embedded in helical layers remained functional throughout the entire test, confirming the long-term monitoring capability under high-pressure oil environments. This study demonstrates a practical embedded-sensing approach compatible with the filament-winding process, providing experimental support for fatigue-life evaluation and in-service safety monitoring of high-pressure hydrogen storage vessels. Full article

Type-IV composite overwrapped pressure vessels (COPVs) enable efficient hydrogen storage but experience severe thermal and mechanical loads that threaten structural integrity, necessitating reliable condition monitoring. This work investigates pseudo-elastic shape-memory alloy (SMA) strain gauges as a cost-effective alternative to fiber-optic systems for monitoring COPVs. Their performance was characterized on composite specimens using four-point bending tests. Additionally, a finite element model analyzed surface-strain behavior as a function of COPV geometry parameters and ambient temperature, enabling identification of optimal quarter-bridge measurement configurations. Full article

Type IV composite overwrapped pressure vessels—characterized by a polymer liner fully wrapped in fiber-reinforced polymer—are emerging as lightweight, corrosion-proof alternatives to traditional metal cylinders in fire safety applications. This paper presents a comprehensive review of Type IV high-pressure vessels used in portable fire extinguishers and self-contained breathing apparatus (SCBA) systems. We outline recent material innovations for both the non-metallic liners and composite shells, including multilayer liner designs (e.g., high-barrier polymers and nanocomposites) and advanced fiber/resin systems. Key manufacturing developments such as automated filament winding, resin infusion, and in-line non-destructive testing are discussed. Technical performance in fire applications is critically examined: current standards and certification requirements (EU and international), typical design pressures (e.g., 300 bar in SCBA) and safety factors, common failure modes (liner collapse, fiber rupture, etc.), inspection protocols, and a comparison with Type IV hydrogen storage cylinders. Market trends are also reviewed, highlighting the major manufacturers and the growing adoption of composite extinguishers (e.g., 20-year service-life composite units) versus conventional steel. The review draws on 7–10 peer-reviewed studies to analyze the state of the art, finding that Type IV vessels offer significant weight reduction (>30%) and corrosion resistance at the cost of more complex design and certification. In firefighting use, these cylinders demonstrably improve firefighter mobility and reduce maintenance, while meeting rigorous safety standards. Remaining challenges include further improving liner permeability barriers to prevent gas leakage or collapse, understanding long-term composite aging under cyclic loads, and optimizing fire resistance. Overall, Type IV composite pressure vessels represent a major innovation in fire suppression technology, enabling safer and more efficient extinguishing equipment. Future research and standardization efforts are recommended to fully realize their benefits in fire protection. Full article

A vibration-based protocol is presented for identifying barely visible impact damage (BVID) in type-IV composite-overwrapped pressure vessels (COPVs). A 1 kJ hemispherical-tip strike was applied to a fully pressurized vessel, which was subsequently depressurized and characterized by free–free experimental modal analysis over a 168-point grid. The frequency response functions (FRFs) at the impact meridian exhibited distinct peaks near 3.70, 4.34, and 4.90 kHz with larger amplitudes and lower coherence than at the diametrically opposite meridian, indicating local circumferential stiffness loss. A detailed finite element model of the liner, bosses, and carbon/epoxy overwrap was updated by idealizing a cylindrical sub-volume with a 90% reduction in orthotropic stiffness. The pristine and “damaged” numerical modal sets agreed closely (mean frequency error < 2%), and for most of the first 60 modes, the diagonal Modal Assurance Criterion (MAC) remained ≥ 0.90. However, in several nearly degenerate circumferential mode pairs, the diagonal MAC dropped to 0.49–0.88 because the local asymmetry rotated the eigenvectors within a common subspace, showing that classical MAC alone cannot expose such early-stage defects. Radial displacement scan-lines provided the missing spatial resolution. Modes whose antinodal regions intersect the dent showed pronounced local amplitude bulges and slight angular shifts in the peak toward the impact site, whereas modes with a nodal line across the damage were virtually unchanged. The combined use of FRF asymmetry, MAC screening, and scan-line deformation profiling localized the impact to the correct circumferential sector with centimeter-scale resolution along the scan ring, yielding predictive signatures for rapid, non-pressurized in situ assessment of impacted COPVs after depressurization. Full article

Composite pressure vessels have attracted significant attention in recent years owing to their lightweight characteristics and superior mechanical performance. However, analyzing composite layers remains challenging due to complex filament-winding (FW) pattern structures and the associated high computational costs. This study introduces a homogenization method to achieve cross-scale modeling of carbon fiber-reinforced plastic (CFRP) layers, accounting for both lay-up sequence and in-plane FW diamond-shaped form. The stacking sequence in an FW Type IV composite pressure vessel is numerically investigated through ply modeling and cross-scale homogenization. The composite tank structure, featuring a polyamide PA66 liner, is designed for a working pressure of 70 MPa and comprises 12 helical winding layers and 17 hoop winding layers. An FW cross-undulation representative volume element (RVE) is developed based on actual in-plane mesostructures, suggesting an equivalent laminate RVE effective elastic modulus. Furthermore, six different lay-up sequences are numerically compared using ply models and fully and partially homogenized models. The structural displacements in both radial and axial directions are validated across all modeling approaches. The partial homogenization method successfully captures the detailed fiber-direction stress distribution in the innermost two hoop or helical layers. By applying the Hashin tensile failure criterion, the burst pressure of the composite tank is evaluated, revealing 7.56% deviation between the partial homogenization model and the ply model. Fatigue life analysis of the Type IV composite pressure vessel is conducted using ABAQUS^® coupled with FE-SAFE, incorporating an S-N curve for polyamide PA66. The results indicate that the fatigue cycles of the liner exhibit only 0.28% variation across different stacking sequences, demonstrating that homogenization has a negligible impact on liner lifecycle predictions. The proposed cross-scale modeling framework offers an effective approach for multiscale simulation of FW composite pressure vessels, balancing computational efficiency with accuracy. Full article

This paper provides a comprehensive review of Type IV hydrogen tanks, with a focus on materials, manufacturing technologies and structural issues related to high-pressure hydrogen storage. Recent advances in the use of advanced composite materials, such as carbon fibers and polyamide liners, useful for improving mechanical strength and permeability, have been reviewed. The present review also discusses solutions to reduce hydrogen blistering and embrittlement, as well as exploring geometric optimization methodologies and manufacturing techniques, such as helical winding. Additionally, emerging technologies, such as integrated smart sensors for real-time monitoring of tank performance, are explored. The review concludes with an assessment of future trends and potential solutions to overcome current technical limitations, with the aim of fostering a wider adoption of Type IV tanks in mobility and stationary applications. Full article

This study investigates the hydrogen permeability of injection-molded polyamide 6 (PA6) nanocomposites reinforced with organo-modified montmorillonite (OMMT) at varying concentrations (1, 2.5, 5, and 10 wt. %) for potential use as Type IV composite-overwrapped pressure vessel (COPV) liners. While previous work examined their mechanical properties, this study focuses on their crystallinity, morphology, and gas barrier performance. The precise inorganic content was determined using thermal gravimetry analysis (TGA), while differential scanning calorimetry (DSC), wide-angle X-ray diffraction (WAXD), and scanning electron microscopy (SEM) were used to characterize the structural and morphological changes induced by varying filler content. The results showed that generally higher OMMT concentrations promoted γ-phase formation but also led to increased agglomeration and reduced crystallinity. The PA6/OMMT-1 wt. % sample stood out with higher crystallinity, well-dispersed clay, and low hydrogen permeability. In contrast, the PA6/OMMT-2.5 and -5 wt. % samples showed increased permeability, which corresponded to WAXD and SEM evidence of agglomeration and DSC results indicating a lower degree of crystallinity. PA6/OMMT-10 wt. % showed the most-reduced hydrogen permeability compared to all other samples. This improvement, however, is attributed to a tortuous path effect created by the high filler loading rather than optimal crystallinity or dispersion. SEM images revealed significant OMMT agglomeration, and DSC analysis confirmed reduced crystallinity, indicating that despite the excellent barrier performance, the compromised microstructure may negatively impact mechanical reliability, showing PA6/OMMT-1 wt. % to be the most balanced candidate combining both mechanical integrity and hydrogen impermeability for Type IV COPV liners. Full article

Type IV composite overwrapped pressure vessels (COPVs) store hydrogen at pressures up to 70 MPa and must meet stringent safety standards through physical testing. However, full-scale burst, plug torque, axial compression, impact, and drop tests are time-consuming and costly. This study proposes a unified finite element analysis (FEA) workflow that replicates these mandatory tests and predicts failure behavior without physical prototypes. Axisymmetric and three-dimensional solid models with reduced-integration elements were constructed for the polyamide liner, aluminum boss, and carbon/epoxy composite. Burst simulations showed that increasing the hoop-to-axial stiffness ratio shifts peak stress to the cylindrical region, promoting a longitudinal rupture—considered structurally safer. Plug torque and axial load simulations revealed critical stresses at the boss–composite interface, which can be reduced through neck boss shaping and layup optimization. A localized impact with a 25 mm sphere generated significantly higher stress than a larger 180 mm impactor under equal energy. Drop tests confirmed that 45° oblique drops cause the most severe dome stresses due to thin walls and the lack of hoop support. The proposed workflow enables early-stage structural validation, supports cost-effective design optimization, and accelerates the development of safe hydrogen storage systems for automotive and aerospace applications. Full article

Due to environmental concerns and increasing energy needs, hydrogen is increasingly seen as a promising alternative to fossil fuels. Its advantages include minimal greenhouse gas emissions (depending on origin), high efficiency, and widespread availability. Various storage methods have been developed, with high-pressure storage being currently among the most common due to its cost-effectiveness and simplicity. Composite high-pressure vessels are categorized as type III or IV, with type III using an aluminum alloy liner and type IV utilizing a polymer liner. This paper investigates damage mechanisms in filament wound carbon fiber composite pressure vessels subjected to low-velocity impacts, focusing on two types of impactors (with different geometries) with varying impact energies. The initial section features experimental trials that capture various failure modes (e.g., matrix damage, delamination, and fiber breakage) and how different impactor geometries influence the damage mechanisms of composite vessels. A numerical model was developed and validated with experimental data to support the experimental findings, ensuring accurate damage mechanism simulation. The research then analyzes how the shape and size of impactors influence damage patterns in the curved vessel, aiming to establish a relationship between impactor geometry features and damage, which is crucial for the design and applications of carbon fiber composites in such an engineering application. Full article

Achieving the required decarbonisation targets by the shipping industry requires a transition to technologies with zero or near-zero greenhouse gas (GHG) emissions. One promising shipping fuel with zero emission of exhaust gases (including CO₂) is green hydrogen. This type of fuel, recognised as a 100% clean solution, is being investigated for feasible use on a service offshore vessel (SOV) working for offshore wind farms. This study aims to examine whether hydrogen may be used on an SOV in terms of the technical and economic challenges associated with the design process and other factors. In the analyses, a reference has been made to the current International Maritime Organization (IMO) guidelines and regulations. In this study, it was assumed that hydrogen would be directly combusted in a reciprocating internal combustion engine. This engine type was reviewed. In further research, hydrogen fuel cell propulsion systems will also be considered. The hydrogen demand was calculated for the assumed data of the SOV, and then the volume and number of high-pressure tanks were estimated. The analyses revealed that the SOV cannot undertake 14-day missions using hydrogen fuel stored in cylinders on board. These cylinders occupy 66% of the ship’s current volume, and their weight, including the modular system, accounts for 62% of its deadweight. The costs are over 100% higher compared to MDO and LNG fuels and 30% higher than methanol. The actual autonomy of the SOV with hydrogen fuel is 3 days. Full article

This study focuses on polyamide 6/organo-modified montmorillonite (PA6/OMMT) nanocomposites as potential liner materials, given the growing interest in enhancing the performance of type IV composite overwrapped hydrogen storage pressure vessels. The mechanical properties of PA6/OMMT composites with varying filler concentrations were investigated across a temperature range relevant to hydrogen storage conditions (−40 °C to +85 °C). Liner collapse, a critical issue caused by rapid gas discharge, was analyzed using an Ishikawa diagram to identify external and internal factors. Mechanical testing revealed that higher OMMT content generally increased stiffness, especially at elevated temperatures. The Young’s modulus and first yield strength exhibited non-linear temperature dependencies, with 1 wt. per cent OMMT content enhancing yield strength at all tested temperatures. Dynamic mechanical analysis (DMA) indicated that OMMT improves the storage modulus, suggesting effective filler dispersion, but it also reduces the toughness and heat resistance, as evidenced by lower glass transition temperatures. This study underscores the importance of optimizing OMMT content to balance mechanical performance and thermal stability for the practical application of PA6/OMMT nanocomposites in hydrogen storage pressure vessels. Full article

Compressed gas storage of hydrogen has emerged as the preferred choice for fuel cell vehicle manufacturers, as well as for various applications, like road transport and aviation. However, designers face increasing challenges in designing safe and efficient composite overwrapped pressure vessels (COPVs) for hydrogen storage. One challenge lies in the development of precise software programs that consider a multitude of factors associated with the filament winding process. These factors include layer thickness, stacking sequence, and the development of particularly robust models for the dome region. Another challenge is the formulation of predictive behavior and failure models to ensure that COPVs have optimal structural integrity. The present study offers an exploration of numerical methods used in modeling COPVs, aiming to enhance our understanding of their performance characteristics. The methods examined include finite element analysis in Abaqus, involving conventional shell element, continuum shell element, three-dimensional solid element, and homogenization techniques for multilayered composite pressure vessels. Through rigorous comparisons with type-III pressure vessels from the literature, the research highlights the most suitable choice for simulating COPVs and their practicality. Finally, we propose a new design for type-IV hydrogen composite pressure vessels using one explored method, paving the way for future developments in this critical field. Full article

Hydrogen has attracted global attention as a clean secondary energy source and has numerous possible applications, including fuel for vehicles. To store the hydrogen effectively, ammonia is considered promising due to high hydrogen density, stability, and total energy efficiency. Adopting ammonia as a fuel in vehicles requires a proper fuel tank design to fulfill the required volumetric content and safety standards, without neglecting the economic objectives. In general, a type-IV pressure vessel is utilized as a fuel tank because it is the lightest one, compared to other types of pressure vessel. This paper focuses on the effort to develop a lightweight type-IV ammonia pressure vessel designed for mobility vehicles. The material combination (liner and composite) and composite stacking sequence are analyzed for both burst and impact tests by using a finite element method. Two polymer materials of polyethylene terephthalate (PET) and polypropylene (PP) are evaluated as the liner considering their ultimate tensile strength, density, cost, and compatibility with ammonia, while carbon-fiber-reinforced polymer (CFRP) and glass-fiber-reinforced polymer (GFRP) are adopted as composite skins. In addition, five composite stacking sequences are analyzed in this study. Von Mises stress and Hashin’s damage initiation criteria are used to evaluate the performance of liner and composite, respectively. As the results, PP-based pressure vessels generate lower stress in the liner compared to PET-based vessels. In addition, CFRP-based pressure vessels have a higher safety margin and are able to generate lower stress in the liner and lower damage initiation criteria in the composite skin. The material combination of PP-CFRP with a stacking sequence of [90/±30/90]_3s gives the lowest maximum stress in the liner during the burst test, while, for the impact test, the stacking sequence of [90/±θ/90]_3s is considered the most appropriate option to realize a lower stress at the liner, although this tendency is relatively small for vessels with PP liner. Full article