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Zhang 2020
Zhang 2020
Composite Structures
journal homepage: www.elsevier.com/locate/compstruct
A R T I C LE I N FO A B S T R A C T
Keywords: The aim of this study is to propose methods for dome thickness distribution and the charge pressure of the liner
Composite material for a 70 MPa type IV hydrogen storage vessel. The netting theory was employed to design the lay-up of the
Type IV hydrogen vessel cylindrical section. For precise prediction of the dome thickness, a cubic spline function was utilized. Variable
Filament winding polar radii were used to reduce the fiber stacking and thickness accumulation near polar openings. To evaluate
Winding tension
the designed lay-up, various failure criteria were applied so as to predict precisely the failure of composite layers
Variable polar radii
in finite element analysis. In order to determine the most appropriate range of the internal pressure when filling
hydrogen gas during filament winding process, the compressive pressure applied on the liner was calculated by
taking into account the variety of winding tension, and the buckling and static analysis of the liner were carried
out, respectively. The methods presented in this work provide a valuable reference for designing the type IV
hydrogen storage vessels.
1. Introduction simulated annealing and the weight was significantly reduced. Since
the operating pressure of the hydrogen pressure vessel determines the
Hydrogen gas, owing to the advantages of renewability and pro- driving range of fuel cell vehicles, a greater driving range can be
ducing harmless byproducts, has gained sufficient attention as a source achieved by increasing the pressure of hydrogen. The weight of com-
of eco-friendly energy [1,2]. Various storage technologies have been posite pressure vessel, however, increases, which leads to high manu-
developed to utilize the hydrogen as a fuel source in aerospace and facturing costs. In order to fabricate light-weight high-pressure hy-
commercial industries [3,4]. Considering the performances and weight drogen storage vessels to accelerate the commercialization of hydrogen
of the storage structure, the composite pressure vessel which can be in the automotive industry, type IV high pressure storage vessels have
used to store hydrogen gas at a high pressure is the most economical received much attention. These vessels are fabricated by composite
choice. wound around a polymer liner. To satisfy industry’s specifications such
At present the vessels which are extensively used to store hydrogen as volumetric hydrogen density, the internal pressure must be increased
gas are composite pressure vessels with metallic liners (type III pressure up to 70 MPa. Recently, researches on type IV pressure vessels have
vessels). Since the metallic liner has many advantages such as high been carried out. Ramirez et al. [11] predicted the burst pressure of
anticollision performance, excellent impermeability and distinct plas- type IV hyperbaric tanks for hydrogen storage with the aid of finite
ticity that improve the entire performance of composite vessels by ap- element analysis, and the results were validated by experiments. Leh
plying autofrettage pressure, the considerable investigations on the et al. [12] established a progressive model to predict the burst pressure
type III pressure vessels have been carried out. Son et al. [5] predicted of a type IV hydrogen composite pressure vessel and proposed a method
the autofrettage pressure of a type III hydrogen pressure vessel based on for predicting the multi-sequence lay-up of a dome by taking into ac-
various failure criteria of anisotropic composites, and evaluated dif- count the variety of winding angles and thickness [13]. Magneville
ferent modeling techniques for the type III hydrogen pressure vessel at et al. [14] employed a thermo-mechanical behavior law to study the
high pressure of 70 MPa [6]. Zu et al. [7–9] investigated type III burst behavior of a hydrogen high pressure storage vessel. Gentilleau
pressure vessels with various shapes of metallic liners. Alcántar et al. et al. [15] took into account the thermo-mechanical stresses caused by
[10] optimized a type III pressure vessel using genetic algorithms and fast filling and studied the effect of temperature and matrix cracking on
⁎
Corresponding authors.
E-mail addresses: jiaxl@mail.buct.edu.cn (X. Jia), zulei@hfut.edu.cn (L. Zu).
https://doi.org/10.1016/j.compstruct.2020.111915
Received 25 November 2019; Received in revised form 1 January 2020; Accepted 9 January 2020
Available online 11 January 2020
0263-8223/ © 2020 Elsevier Ltd. All rights reserved.
Q. Zhang, et al. Composite Structures 236 (2020) 111915
the composite pressure vessel with a polyurethane liner. The afore- Table 1
mentioned literatures about type IV pressure vessels mainly focus on Mechanical properties of 6061-T6 and the polyethylene liner.
the optimization of lay-up, the failure analysis of composite layers or Aluminum boss Polyethylene liner
the prediction of burst pressure. Few investigations on improvement of
dome thickness distribution on dome parts were carried out. Ad- Property 6061-T6 7149U
Elasticity modulus, GPa 74.12 0.33
ditionally, since the stiffness of the polymer liner much lower than that
Poisson's ratio 0.28 0.4
of the aluminum liner, it is necessary to take into account the effect of Tensile strength 368 MPa
winding tension on the polymer liner during filament winding process. Yield Strength 281 MPa 14 MPa
It should be also remembered that the internal pressure generated by Density 930 kg/m3
filling hydrogen gas is used to bear the compressive stress generated by
winding tension. However, the smaller internal pressure would lead to
buckling of the liner under the large winding tension and the larger Table 2
internal pressure would result in destruction of the liner; therefore, it is Material property of T700/epoxy composite.
of great importance to determine the appropriate range of internal property T700/epoxy composite
pressure as filling hydrogen gas. Nevertheless, few studies considering
Extensional modulus in 1- direction (E11) 134,000 MPa
these factors can be available in present literatures.
Extensional modulus in 2- direction (E22) 7420 MPa
In this study, methods for designing the lay-up and determining the Extensional modulus in 3- direction (E33) 7420 MPa
range of internal pressure of the polymer liner were presented. The lay- Shear Modulus (G12) 3710 MPa
up of the storage vessel was designed based on the netting theory. A Shear Modulus (G23) 3710 MPa
cubic spline function was utilized to precisely predict the dome thick- Shear Modulus (G13) 4790 MPa
Poisson’s ratio (μ12) 0.28
ness, and variable polar radii were used to reduce the fiber stacking and Poisson’s ratio (μ23) 0.28
thickness accumulation on dome parts especially near polar openings. Poisson’s ratio (μ13) 0.3
In order to ensure the liner undestroyed in filament winding process, it Longitudinal tensile Strength (Xt) 2300 MPa
is of importance to determine the appropriate internal pressure. The Longitudinal compressive Strength (Xc) 1250 MPa
Transverse Tensile Strength in (Yt) 74 MPa
effect of winding tension on the liner was therefore investigated in
Transverse compressive (Yc) 180 MPa
order to obtain the compressive stress in radial direction. Combining Shear Strength (S) 50 MPa
the compressive stress generated by winding tension with the buckling Developed fiber strength (σf) 2800 MPa
analysis of the liner, the minimum internal pressure was determined.
Additionally, the static analysis of the liner was carried out to obtain
the maximum internal pressure. variety of the compressive stress in radial direction. To investigate the
effect of the compressive stress on the liner, the compressive stress is
calculated and expressed as [16]:
2. Geometry and material properties
P = F ·sin θ (b·R) (1)
As can be seen in Fig. 1, the pressure vessel modeled in this paper is
a type IV hydrogen storage vessel with capacities of 70 MPa, composed where F is the winding tension; b is the roving bandwidth that is 2 mm
of a metal boss playing the role of connecting the vessel, a polyethylene in this work; R is the radius corresponding to the composite layer.
liner used to seal the vessel and the composite layer whose role is to
ensure the strength of the structure. The properties of the aluminum
boss and the polyethylene liner are shown in Table.1. The material 2.2. Thickness prediction of the cylindrical section
property of T700 fiber reinforced composites is listed in Table. 2.
The netting theory [17] as a simple and well-suited method for the
2.1. Compressive stress generated by winding tension design of filament-wound pressure vessels assumes that the fibers
support all the internal pressure and the failure of the structure occurs
In filament winding process, as the layers increase the winding due to fiber breakage; therefore, the effect of the matrix is negligible.
tension in outer layers is greater than that of internal layers; therefore, Based on the netting theory, the thickness of composite layers is shown
the fiber stress in the internal layers will decrease, which leads to the as
2
Q. Zhang, et al. Composite Structures 236 (2020) 111915
Rp
tθ = (2 − tan2 α )
2σf (2)
Rp
ta =
2σf cos2 α (3)
where tθ and ta are the thickness of hoop layers and helical layers, re-
spectively; p represents the burst pressure; R stands for the outside ra-
dius of the liner; σf is the developed fiber strength; α is the winding
angle.
Combining Eq. (2) with Eq. (3), the thickness of cylindrical part is
obtained by
3Rpb
t = t θ + ta =
2σf (4)
The burst pressure is calculated by Eq. (4), given by
2tσf
pb =
3R (5)
Since only helical layers are wound during dome winding, the fiber
strength cannot achieve the level of hoop winding. As a result, the Fig. 2. Layer thickness distribution on dome parts corresponding to various
thickness of helical layers is introduced as rovings.
Rp
tak =
2ks σf cos2 α (6) to various rovings was carried out and compared in order to determine
the appropriate roving bandwidth, as shown in Fig. 2. It is illustrated
where ks is the stress equilibrium factor. Taking it into account, the
that the layer thickness increases sharply in the region of two roving
thickness of helical layers increases; however, the thickness of hoop
bandwidths around polar openings as a single roving is utilized in fi-
layers decreases and can be expressed as
lament winding process, which demonstrates the fiber builds up ser-
Rp ⎛ 1 iously. As the rovings increase, the layer thickness decreases sig-
tθk = 2 − tan2 α ⎞
⎜ ⎟
2σf ⎝ ks ⎠ (7) nificantly and the sharply thickness peak near polar openings can be
avoided. However, using excessive roving bandwidth is not re-
Combining Eq. (6) with Eq. (7), the total thickness of composite commended, as this leads to non-uniform fiber tension within rovings
layers at cylindrical part is obtained as during dome winding. Thus, the four rovings are employed in this work.
(2ks + 1) Rpb As can be seen in Fig. 2, the fiber stacks and the thickness accu-
tk = tθk + tak = mulates around polar openings although the four rovings are utilized.
2ks σf (8)
Therefore, in this study variable polar radii were used to reduce the
The burst pressure is now introduced thickness accumulation and fiber stacking on the dome part. The
2ks tk σf winding angles obtained using variable polar radii are shown in Table.
pb = 3.
(2ks + 1) R (9)
To make the strength of helical layers unchanged after reducing the
thickness using variable polar radii, the burst pressure is now given by
2.3. Dome thickness prediction
2ks σf tc ncos2 α 0
pb =
By comparing the methods for thickness determination [18], Wang’s R (13)
method [19] was employed in order to predict layer thickness in this
where tc is the thickness of a single roving, which is 0.227 mm, α0 is the
study as it is taken as the most accurate method. It is depicted in two
average winding angle on dome parts, which is computed by winding
parts:
angles corresponding to variable polar radii.
mR ·nR ⎧ r r + b ⎞⎫ The safety factor in this paper is 2.5, the predicted burst pressure is
t (r ) = · arccos ⎛ 0 ⎞ − arccos ⎛ 0 ·tp, (r2b ⩽ r ⩽ R)
π ⎨ ⎩ ⎝r ⎠ ⎝ r ⎠⎬ ⎭ (10) thus 175 MPa. Additionally, the stress equilibrium factor ks is 0.75.
According to Eq. (6), the thickness of helical layers on cylindrical part is
and determined and the corresponding number of helical layers is 34.
t (r ) = m1 + m2 × r + m3 × r 2 + m4 × r 3, (r0 ⩽ r ⩽ r2b) (11)
Table 3
where mR and nR stand for the number of rovings and layers in the Winding angles corresponding to variable polar radii.
cylindrical section, respectively, and their quantities are expressed as
Winding angle (°) Winding angle after rounding Radii of polar openings
2πR (°) (mm)
⎧ mR = (b cos α 0 )
tR
⎨ nR = 13.8 14 40
2tp (12)
⎩ 16.6 17 47.93
19.4 19 55.82
tp represents the thickness of a roving, b stands for the width of a 22.3 22 63.68
roving, r0 is the radius of the polar opening, r2b is the radius at two 25.2 25 71.5
roving-width distance from the polar openings, tR and α0 represent the 28.2 28 79.25
thickness of the layer and the initial winding angle on the cylindrical 31.2 31 86.95
34.2 34 94.56
part, respectively. The coefficients m1, m2, m3 and m4 are presented in
37.4 37 102.09
[19] and determined with the aid of boundary conditions. 40.7 41 109.5
In this work the thickness prediction of the dome part corresponding
3
Q. Zhang, et al. Composite Structures 236 (2020) 111915
Table 4 The Tsai-Wu failure criterion [20] was employed to detect the da-
Composite layers for winding angles that are calculated using variable polar mage onset, given by
radii.
Fi σi + Fij σi σj ⩽ 1(i, j = 1, 2, 6) (14)
Winding angle (°) 14 17 19 22 25 28 31 34 37 41
where the strength parameters F11, F22, F12, F66, F1, F2 and F6 are de-
Layers 12 4 4 4 4 2 2 2 2 2
fined as
1 1 1 1
F11 = , F22 = , F66 = 2 , F12 = − ,
Xt Xc Yt Yc S 2 Xt Xc Yt Yc
1 1 1 1
F1 = − , F2 = − , F6 = 0
Xt Xc Yt Yc (15)
4
Q. Zhang, et al. Composite Structures 236 (2020) 111915
strain in liner is −8219με, (the negative value indicates the shrinkage greater than the fiber strain, illustrating the fibers are relaxed so that
of the liner in hoop direction, while the positive value illustrates the the fiber stresses disappear. After the three composite layers are wound
outward expansion) and the hoop strain in fibers is 740με. Moreover, completely, the equivalent pressure on the liner is 0.177 MPa. The hoop
the hoop strain of the liner changes by 7197με. stain of the liner is −1987με, and the fiber stain in the third layer is
As the third layer is wound, the compressive stress in radial direc- 240με, as shown in Fig. 10-d.
tion is 0.043 MPa. Considering the relaxation effect of the second layer When starting the winding of the fourth layer, the third layer relaxes
on the first layer, the hoop strain generated by shrinkage of the liner is the internal layers. The compressive stress resulting from the four layers
5
Q. Zhang, et al. Composite Structures 236 (2020) 111915
Table 5
Stiffness degradation criteria of composite materials.
Failure modes Stiffness degradation criteria
Matrix Cracking E22 = 0.2 E22, G12 = 0.2 G12, G23 = 0.2 G23
Fiber tensile failure E11 = 0.07E11, E22 = 0.07E22, E33 = 0.07E33, G12 = 0.07G12, G13 = 0.07G13, v12 = 0.07v12, μ23 = 0.07μ23, μ13 = 0.07 v13
Shear failure G12 = v12 = 0
Delamination caused by tensile E33 = G23 = G13 = μ23 = μ13 = 0
Delamination caused by compression E33 = G23 = G13 = μ23 = μ13 = 0
Fig. 6. Stress distribution in the boss and the liner: (a) mises stress distribution in the boss; (b) mises stress distribution in the liner.
Fig. 7. Stress distribution in composite layers: (a) stress in longitudinal direction; (b) stress in transverse direction; (c) shear stress.
6
Q. Zhang, et al. Composite Structures 236 (2020) 111915
Fig. 8. Strain distribution in composite layers: (a) strain in longitudinal direction; (b) strain in transverse direction; (c) shear strain.
is 0.086 MPa, and the hoop strain in the liner is 441με, which shows compressive stress is 0.17 MPa. It is concluded that the liner begins to
that the liner begins to expand outward. Nevertheless, due to the shrink and the fiber stresses in internal layers disappear in different
stiffness of the fiber that is much greater than that of the liner, the hoop proportions. The entire winding process is carried out with following
strain of the liner is unchanged. the rules mentioned above. As the layers increase, the compressive
When the fifth layer is wound, the compressive stress generated by stress will fluctuate around 0.15 MPa.
winding tension in the five layers is 0.128 MPa. Since it is smaller than
the charge pressure of 0.15 MPa, the hoop strain in the liner is constant
as well; however, after the sixth layer is wound completely, the 4.1.1. Buckling analysis of the liner
To determine the ultimate pressure of the liner, the buckling
Fig. 9. Results calculated by progressive failure analysis: (a) fiber failure (b) matrix failure (c) shear failure.
7
Q. Zhang, et al. Composite Structures 236 (2020) 111915
Fig. 10. Variety of hoop strains in the liner: (a) hoop strains under the internal pressure of 0.15 MPa, (b) hoop strains as the first layer is wound, (c) hoop strains as
the second layer is wound, (d) hoop strains as the third layer is wound, (e) hoop strains as the fourth layer is wound.
analysis was carried out in this study. Under the external pressure of equal to the yield strength while the step time is 0.5442 MPa; the ul-
0.01 MPa, the first four modes of the liner are shown in Fig. 11. It timate internal pressure is thus 0.5442 MPa. Owing to the expansion of
illustrates that the eigenvalue corresponding to the first order mode is the gas caused by the increasing temperature in curing process, the
2.2312 that is the minimum. Therefore, the ultimate pressure is internal pressure increases as well. In this study the initial temperature
0.0223 MPa. Under the fiber tension of 45 N, the compressive stress is 23℃, and the maximum curing temperature is 120℃; thus, the ulti-
resulting from the first layer is 0.133 MPa, which is greater than the mate internal pressure reaches 0.41 MPa, when the internal pressure
ultimate pressure of 0.0223 MPa. In order to ensure the liner be able to increases by 33% according to the ideal gas law. It should be also re-
bear the compressive stress, the minimum internal pressure when filling membered that the total compressive stress is about 0.15 MPa, there-
hydrogen gas is 0.11 MPa. fore, the appropriate internal pressure should range from 0.11 to
0.15 MPa.
4.1.2. Static analysis of the liner
The static analysis of the liner under the initial internal pressure of 5. Conclusion
1 MPa was complemented so as to predict the ultimate internal pres-
sure, as shown in Fig. 12. The maximum mises stress is 14 MPa that is In this paper methods for predicting the dome thickness and the
8
Q. Zhang, et al. Composite Structures 236 (2020) 111915
burst of the storage vessel does not take place. Additionally, the com-
pressive stress generated by winding tension was calculated. By buck-
ling analysis and static analysis of the liner, the appropriate internal
pressure as filling hydrogen gas ranges from 0.11 to 0.15 MPa. It is
believed that the present methods in this study could prove very useful
in the design stage of type IV hydrogen storage vessel.
Xiaolong Jia planned the project and provided financial support for
this research activity. Lei Zu formulated overarching research goals and
aims. Qian Zhang developed methodology and created models and
participated in drafting the manuscript. Hui Xu implemented the nu-
merical simulation and experiments and participated in drafting the
manuscript. Huabi Wang validated the formulations and participated in
drafting the manuscript. Shuo Cheng helped to perform the experiments
and edit the manuscript.
Acknowledgements
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Q. Zhang, et al. Composite Structures 236 (2020) 111915
Appendix A. Supplementary data using genetic algorithm and simulated annealing. Int J Hydrogen Energy 2017.
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storage vessel burst e Simulation and experimental validation. Int J Hydrogen
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IV hydrogen composite pressure vessel. Int J Hydrogen Energy
2015;40(38):13206–14.
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