Composite Overwrapped Pressure Vessels Research Articles

Optimizing performance of hybrid fiber reinforced overwrapped pressure vessel

Composite overwrapped pressure vessels (COPVs) offer significant weight advantages over traditional all-metal vessels particularly in industries like aerospace, automotive and pharmaceutical, but pose unique challenges in mechanical design, fabrication, and testing. Despite their benefits, COPVs are susceptible to stress rupture failure, which can lead to catastrophic consequences during operation. This failure mode is not fully understood, with burst pressure-induced extreme stress concentrations and dynamic loading primarily contributing to rapid deformation and strain. To address these concerns, a comprehensive investigation was conducted, focusing on optimizing and examining the effects of optimum winding angle and lay-up pattern configuration on burst pressure in vessels under internal pressure. Finite element modeling analyzed the burst pressure behavior of COPVs with a 4 mm thick aluminum core cylinder and varying layers of carbon/fiber epoxy, each with a constant thickness. ABAQUS composite modeler generated 18 COPV models with carbon fiber/epoxy plies, ensuring uniform thicknesses while exploring different fiber orientations. The effects of ply stacking sequence were analyzed through finite element analysis for all models, comprising varying layers with uniform thicknesses. Attention was paid to failure criteria, methodically evaluating the burst strength of the Al/CFRPC COPVs This exhaustive analysis yielded an optimal COPV design profile characterized by a precisely calibrated ply stacking sequence of [24.50, −24.50] PP winding pattern and six (6) arranged layers. The stress-strain distribution analysis of the Composite Overwrapped Pressure Vessel (COPV) revealed both a uniform distribution of stress across its surface and extreme stress concentration, particularly peaking towards the polar boss region. This concentration is discernible due to variations in ply thickness induced by the overwrapped fiber orientation. This investigation provides valuable insights for optimizing COPV design and enhancing its performance and reliability in various applications.

Theoretical and experimental research on the critical buckling pressure of the thin-walled metal liner installed in the composite overwrapped pressure vessel

Composite overwrapped pressure vessels (COPVs) are widely used in the field of high-pressure gas storage and transportation because of their light weight and high strength. In engineering, autofrettage is usually used to improve the fatigue life of composite pressure overwrapped vessels with metal liners. However, excessive pressure of autofrettage could cause buckling damage to the metal liner. In order to determine the upper limit of autofrettage (critical buckling pressure) and analyze its influence on the safety factor of COPVs, a theoretical calculation model of the critical buckling pressure about the metal liner was established based on classical laminated plate theory and the confined buckling theory. Then, a COPV with thin-walled welded metal liner was prepared by fiber winding process. In order to monitor and judge the buckling damage mode of the liner, the circumferential strain of the COPV's cylinder was measured by loading and unloading step-by-step. Finally, the influence of materials and dimensions of the metal liner on the pressure ratio (the ratio of the first layer failure pressure to the critical buckling pressure of the COPV's metal liner) was discussed. When the diameter to thickness ratio (R/t) of the metal liner was greater than 35, the pressure ratios of the 6063-T5 aluminum alloy liner and the S30408 stainless steel liner both exceeded 2.25. However, the pressure ratio of 6061-T6 aluminum alloy liner with R/t ≤ 60 was lower than 1.85, which shows that the metal liner with higher yield strength and lower elastic modulus has higher utilization rate of fiber winding layers. Due to the fact that the current design standards only ensure the reliability of COPVs through safety factors and various type testing with their evaluation methods, the proposed theoretical calculation method can reduce the uncertainty of COPVs during the design and testing rounds.

Failure monitoring and classification from acoustic emission tests on impact-damaged hydrogen composite pressure vessels

Composite overwrapped pressure vessels (COPV) for hydrogen will play an important role in emission free mobility and energy storage. The DELFIN project (2018 – 2022) was set up with the goal of developing improved COPVs that are lighter, cheaper and more durable. A key aspect of this project was to conduct full-scale impact tests with different gas pressure levels that were used to evaluate the vessels’ crash performance and to verify numerical impact simulations. These tests were followed by controlled pressure experiments until the burst pressure was reached. The procedure was monitored with acoustic emission testing (AT) and subsequent computer tomography (CT). The residual COPV stability and the AT results are compared to different scenarios regarding the impact energies and impact angles. The event localization from AT shows a clear correlation of the emitted energy with the damaged areas. We classify the recorded signals into groups that can be related to the failure mechanism and compare those to the pressure evolution before failure of the COPV. All tests indicate that large impact energies lead to a significant reduction of the burst pressure of COPVs, whereas a higher internal pressure can have a stabilizing effect that reduces the damaging effect.

Feasibility study of carbon-fiber reinforced polymer linerless pressure vessel tank

Composite pressure vessels are used in aerospace engineering for storing fluids such as propellants, nitrogen, and oxygen. They are also used in life-support systems, High-performance pressure suits for astronauts, Helium Tanks for Balloons and Airships. Among many types of composites, Carbon fiber composites uses have been increasing due to its high strength to weight ratio, high thermal expansion, corrosion, fatigue and impact resistance and design flexibility. In order to improve the volume of the pressure vessel, the liner-less concept is tried. This increased volume efficiency is crucial in aerospace applications where space is at a premium and maximizing storage capacity within limited dimensions is important. Not only the volume efficiency, but also the Reduced Permeability Concerns, Enhanced Durability and Longevity, better thermal continuity and simplified manufacturing process make this research significant in the area of pressure vessel. This research paper deals with the fabrication and development of a cylinder without a lining. The test sample was subjected to several tests: tensile test, impact, shear test (3P Bending), leak test and Pressure test. The test sample was capable of withstanding 20 Bars without failure. The numerical results were also performed and compared with the experimental results. The difference was only 3%. Unsymmetrical dimethyl hydrazine (UDMH) AND red-fuming nitric acid can both be stored in this cylinder (RFNA). Unlike traditional composite overwrapped pressure vessels, the liner-less composite tanks rely completely on the composite shell to act as a permeation barrier as well as handling all pressure and environmental loads. The absence of a liner eliminates the potential for delamination or failure at the interface between the liner and the composite material.

Impact of stacking sequence on burst pressure in glass/epoxy Type IV composite overwrapped pressure vessels for CNG storage

The shift from metallic to composite pressure vessels for storing compressed natural gas (CNG) is driven by the goal of reducing environmental impact by using lighter higher-performing structures. This work focuses on enhancing the internal pressure strength of a type IV composite overwrapped pressure vessel (COPV) by optimising the stacking sequence of the overwrapping composite layers. Parametric finite element (FE) models are developed to reveal symmetry effects. In these models, both the thickness build-up and fibre angle variation at the turnaround zones are accurately modelled. Subsequently, the stacking sequence is optimised with the objective function of maximising burst strength. The parametric modelling demonstrates that representing the COPV as an axisymmetric continuum reduces computational costs in 5400× while yielding results comparable to full 3D continuum models. Experimental burst tests are carried out to validate the numerical predictions, and the difference in pressure between them is 12.6 %.

Design and material optimization of carbon fiber composite winding reinforcement layer for vehicle Type-IV hydrogen storage vessels

Due to the safety, reliability, and high hydrogen storage density of vehicle Type-IV composite overwrapped pressure vessels (COPVs), the Type-IV COPVs are currently the preferred choice for vehicle hydrogen storage vessels. The reinforcement layer bears 80 % to 90 % of the internal pressure load, and it accounts for a significant proportion of the total cost and weight of Type-IV COPVs. Thus, the reinforcement layer is the key problem in the design and optimization of the vehicle Type-IV COPVs. Firstly, this paper proposed a design method for vehicle Type-IV COPVs considering the strength and stiffness of reinforcement layer, and created the hydrogen storage vessel scheme. Then, the stress and strain of vehicle Type-IV COPVs under working and blasting internal pressure were analyzed by finite element simulation. Finally, the genetic algorithm was used to find the best carbon fiber for vehicle Type-IV COPVs. The results show that the scheme designed by the method in this paper can meet the requirements of vehicle use; The carbon fiber modulus most suitable for car hydrogen storage bottle winding is 288.8 GPa, and the weight of the reinforcement layer is reduced by 32 % compared to the T700S carbon fiber composite wound vessel.

A novel damage localization technique for type III composite pressure vessels based on guided wave mode-matching method

Damage monitoring during the service life of Type III composite overwrapped pressure vessels (COPVs) is crucial for ensuring their safe operation. This paper focuses on the damage localization in COPVs using ultrasonic guided waves structural health monitoring (SHM) techniques. Firstly, dispersion curves were plotted to establish a foundation for experiments and simulations based on the propagation theory of guided waves in multilayered anisotropic structures. Subsequently, a 3D finite element model of COPV was constructed to capture the propagation characteristics of guided waves within the COPV and their interaction with damage. The effects of different fiber angles and fiber layer numbers on guided waves propagation were analyzed, and their interrelationships were established. Furthermore, the “Wave Velocity Directionality” effect of the A0 mode was identified during its propagation in COPV. The monitoring signals obtained from experiments were analyzed to assess the impact of damage on the time-domain and frequency-domain signals of guided waves. Finally, a damage localization algorithm based on mode-matching was proposed, and its localization accuracy was verified in COPVs with different damage locations and fiber layer numbers. The results demonstrate the significant potential of the proposed damage localization algorithm in the damage monitoring of COPV structures.

Automated manufacture and experimentation of composite overwrapped pressure vessel with embedded optical sensor

In recent years, the mobility (air/land) industry has been developing fuel-cell vehicles for mass adoption as hydrogen technology matures. Compared to conventional metallic design, the composite overwrapped pressure vessel without a metal or polymer liner results in a lightweight solution for gaseous hydrogen storage which further improves fuel efficiencies. Since the capabilities of automated fiber placement for making multi-stiffened structures are distinct from other automated manufacturing techniques, this study aimed to evaluate the feasibility of implementing AFP into the manufacture of a small scale COPV with a partially composite liner. The manufacturing related challenges are identified and discussed. During the manufacturing process, Distributed fiber optic sensor was embedded between the plies, as a structural health monitoring solution, to monitor the mechanical performance of the pressurized tank. In addition, finite element study was done to predict the internal strains for different pressure levels and the measured experimental strains at the sensor's location are found to be in close agreement with the finite element results. It is shown that such sensors can be integrated into automated fiber placement manufactured tanks for internal strain monitoring.

Experimental and numerical investigation of radial displacement of COPV using CT and FPP method

The radial displacement of hydrogen storage composite overwrapped pressure vessel (COPV) is a key factor related to the collapse failure and burst pressure. However, there is still lack of effective method to monitor the radial displacement during the hydrostatic test and service process of the vessels. This paper proposed a method to measure the radial displacement based on fringe projection profilometry (FPP). Hydrostatic test with a composite overwrapped pressure vessel verifies the proposed method. The variation of displacement changing with inner pressures observed in the experiments is in agreement with that obtained from finite element analysis. Also Computed Tomography (CT) scanning is conducted and a widely spread micro defects is found in the composite layer of the cylinder. 78.9% of the total observed defects are small (<1000 mm2). In regions where large-sized defects (>1000 mm2) are concentrated, the total area of defects reaches 16,200 mm2. According to the statistical analysis, the strong correlation is found between the defects area and radial displacement.

Application of deep learning for structural health monitoring of a composite overwrapped pressure vessel undergoing cyclic loading

Structural Health Monitoring (SHM) using ultrasonic-guided waves (UGWs) enables continuous monitoring of components with complex geometries and provides extensive information about their structural integrity and their overall condition. Composite Overwrapped Pressure Vessels (COPVs) used for storing hydrogen gases at very high pressures are an example of a critical infrastructure that could benefit significantly from SHM. This can be used to increase the periodic inspection intervals, ensure safe operating conditions by early detection of anomalies, and ultimately estimate the remaining lifetime of COPVs. Therefore, in the Digital Quality Infrastructure Initiative (QI-Digital) in Germany, an SHM system is being developed for COPVs used in a hydrogen refueling station. In this study, the results of a lifetime fatigue test on a Type IV COPV subjected to many thousands of load cycles under different temperatures and pressures are presented to demonstrate the strengths and challenges associated with such an SHM system. During the cyclic testing up to the final material failure of the COPV, a sensor network of fifteen surface-mounted piezoelectric (PZT) wafers was used to collect the UGW data. However, the pressure variations, the aging process of the COPV, the environmental parameters, and possible damages simultaneously have an impact on the recorded signals. This issue and the lack of labeled data make signal processing and analysis even more demanding. Thus, in this study, semi-supervised, and unsupervised deep learning approaches are utilized to separate the influence of different variables on the UGW data with the final aim of detecting and localizing the damage before critical failure.

Guided Wave Behavior in Type IV Composite Overwrapped Pressure Vessels Under Fatigue Loading

Innovative Ultrasonic Guided Wave Approach for Structural Health Monitoring of Type IV Composite Overwrapped Pressure Vessels Seyedreza Hashemi, Jan Heimann, Amir Charmi, Eric Duffner, Jens Prager Abstract: The digitalization of quality control processes and the use of digital data infrastructures is a novel idea that can be applied for ensuring the operational safety and reliability of pressure vessels, particularly in the context of hydrogen storage at high pressure. Despite the critical role these pressure vessels play, current safety regulations lack an established concept for Structural Health Monitoring (SHM). This research addresses this gap by presenting a study on the application of ultrasonic guided waves (GWs) for SHM of Type IV Composite Overwrapped Pressure Vessels (COPVs). The study focuses on the development of a reliable measurement system to transition from conventional periodic inspections to SHM and predictive maintenance, prolonging the remaining lifetime of the vessels. A sensor network is employed, consisting of fifteen piezoelectric wafers arranged in three rings, which are mounted on the outer surface of the COPV. Deploying GWs, known for their long-distance propagation and ability to cover complex structures, the study explores GW behavior under different environmental and operational conditions, including periodic pressure fluctuations and temperature loadings. Meticulous analysis of GW signals by utilizing various features and damage indices, underscores their suitability for an effective SHM under realistic working conditions. The project aims to localize defects by considering temperature, and internal pressure. Mimicking the continuous monitoring of Type IV COPVs in H2 refueling gas stations under authentic operational conditions, the COPV underwent thousands of pressure load cycles in our special test facility . The implemented methodology facilitates early damage detection, showcasing the efficacy of the designed method in effective safety assurance.

Acquiring a Machine Learning Data Set for Structural Health Monitoring of Hydrogen Pressure Vessels at Operating Conditions using Guided Ultrasonic Waves

Hydrogen is an energy source of increasing importance. As hydrogen is very reactive to air and needs to be stored under high pressure, it is crucial to provide safe transportation and storage. Therefore, structural health monitoring, based on guided ultrasonic waves and machine learning methods, is used for Composite Overwrapped Pressure Vessels (COPVs) containing hydrogen. To acquire data that allows robust detection of COPV defects, there are two main process parameters to consider. These are the pressurization of the vessel and the temperature conditions at the vessel. This paper will focus on the derivation of a design of experiment (DoE) from the needs of various validation scenarios (e.g. concerning pressure, temperature or excitation frequency). Practical limitations must be considered as well. We designed experiments with multiple reversible damages at different positions. A network of 25 transducers, structured as five rings with five sensors in one line, is installed on a vessel. Guided ultrasonic waves are used via the pitch-catch procedure, which means that the transducers act pairwise as transmitter and receiver in order to measure all transmitterreceiver combinations. This leads to 600 signal paths, recorded by a Verasonics Vantage 64 LF data acquisition system. Finally, the influences of temperature and pressure within the acquired data set are going to be visualized.

A numerical and experimental study on mechanical behaviours of type III composite vessels with different lay-up sequences

ABSTRACT 5 % .There are various factors that have impact on the burst pressure and the failure mechanism of filament wound composite pressure vessels. The sequence of lay-up was less considered because previous researchers paid little attention on the mechanical performance of the whole vessel. In this paper, a 2D axisymmetric finite element model was proposed to predict the damage evolution, failure strength and failure mode of the composite overwrapped pressure vessels. UMAT subroutine based on Hashin failure criteria was introduced to simulate the progressive damage properties of the composite material. The FE models were validated by comparison with the experimental results, and the error between the numerical simulation results and the experimental results was near 5%. In addition, two schemes were performed to evaluate the effects of different lay-up sequence on the ultimate strength and obtain the optimized scheme of lay-up sequence.

Modeling, fabrication, and burst testing of type-IV 3D printed plastic liner composite overwrapped pressure vessels

Modeling, fabrication, and burst testing of type-IV 3D printed plastic liner composite overwrapped pressure vessels

The optimal design of composite overwrapped pressure vessels based on geodesic dome trajectories using population-based techniques

Pressure vessels are frequently fabricated using composite materials which stand out with their high strength-to-weight ratio, and provide considerable advantages compared to conventional steel ones. In our previous study, the impacts of Polar Opening Radius (POR) on the mechanical characteristics of Composite Overwrapped Pressure Vessels COPVs were numerically examined, and it was determined that effective volume and structural weight responses improved with higher POR, but significant deterioration took place in first-ply interlaminar shear stress (ILSS) responses after 20 mm POR. Therefore, to achieve the best possible mechanical and structural behaviors, the present study aimed to discover an optimum POR that provides maximum internal volume as well as minimum weight and ILSS responses. In this regard, the optimum geodesic dome trajectory based on the 10–30 mm POR range was determined using the Bees Algorithm (BA) and the Particle Swarm Optimization (PSO). According to the findings, the optimum POR was found as 17.9643 and 17.9671 mm due to the BA and PSO algorithms, respectively. Moreover, first-ply ILSS, structural weight and effective internal volume for the optimal COPVs design were achieved as 52.444 MPa, 1070.81 g, and 2721.94 cm3 from the BA, and thus COPVs with maximum strength and minimum structural weight has been designed. In this way, thanks to the optimization studies, an approximately 18.31% improvement in ILSS responses was achieved despite the negligible deterioration in weight and volume compared to the COPVs with a 30 mm POR.

Modal and random vibration responses of composite overwrapped pressure vessels with various geodesic dome trajectories

In the current study, Composite Overwrapped Pressure Vessels (COPVs) with various geodesic dome profiles have been built and their modal and random vibration responses were numerically examined. In this regard, geodesic dome profiles were established for five different polar opening radii of 10, 15, 20, 25, and 30 mm, and thus the impacts of fibre orientations on vibration characteristics depending on the filament winding trajectories were discovered. Furthermore, non-prestressed modal and random vibration responses for COPVs, as well as prestressed vibration behaviours under 50, 100, and 150 Bar internal pressure, were investigated and thus the effects of internal pressure severity on dynamic characteristics were identified. The study found that higher polar opening radius triggered a reduction in the natural frequencies, and these reductions were linked to an increment in the filament winding angle, and a consequent deterioration in the structural stiffness of COPVs. On the other hand, raising the internal pressure severity shifts the natural frequencies to higher frequencies, which are also attributed to ascended structural stiffness. Furthermore, it was established that internal pressure severity and polar opening radius had a coupled effects on the modal and random responses, and that both parameters should be evaluated simultaneously.

On the Multidisciplinary Design of a Hybrid Rocket Launcher with a Composite Overwrapped Pressure Vessel

A multidisciplinary design optimisation (MDO) study of a hybrid rocket launcher is presented, with a focus on quantifying the impact of using composite overwrapped pressure vessels (COPVs) as the oxidiser tank. The rocket hybrid propulsion system (RHPS) consists of a combination of solid fuel (paraffin) and liquid oxidiser (NOx). The oxidiser is conventionally stored in metallic vessels. Alternative design concepts involving composite-based pressure vessels are explored that could lead to significant improvements in the overall performance of the rocket. This design choice may potentially affect parameters such as total weight, thrust curve, and maximum altitude achieved. With this eventual impact in mind, structural considerations such as wall thickness for the COPV are integrated into an in-house MDO framework to conceptually optimise a hybrid rocket launcher.

Model-experiment comparison of quasi static loading on a composite overwrap pressure vessel (Part 2)

A methodology to develop a 3D Finite Element (FE) model of a full metal-lined Composite Overwrapped Pressure Vessel (COPV) was developed and is presented in this paper. The model is intended for prediction of the metal-composite delamination and residual dent depth developed in the metal liner as a result of quasi-static indentation loading. Cohesive elements are used to model the composite and the metal-composite interfaces. Experimental and numerical comparisons of force–displacement curves, delamination area and residual dent depth are presented. Numerical results are in good agreement to the experimental data.

Investigation of Hydrogen Transport Properties through the Liner Material of 70 MPa Type IV Composite Overwrapped Pressure Vessels

In zero-emission solutions for the hydrogen supply chain, high-pressure hydrogen storage in Type IV composite overwrapped pressure vessels (COPVs) is crucial for being safe and secure for a variety of stationary and transport applications. These COPVs consist of a polymeric liner material that works as a barrier for the stored hydrogen, while the carbon fiber-based composite provides the strength to hold the high-pressure hydrogen (of nominal working pressure more than 70 MPa to achieve the competitive driving range). Several experimental studies and simulation work have been performed on the viability of various polymers as low-permeability materials under low-pressure conditions. However, because of their proprietary nature and commercialized research, the characteristics of hydrogen permeation through polymers and their behavior at high pressure are still readily available in the literature. It is a major concern and the most crucial component of Type IV COPVs that these polymeric liners hold high pressure and maintain the necessary density of hydrogen (state of charge) toward operational requirements and safety concerns related to the cause of failures due to permeation (such as blistering, buckling, cracking, and so on). This paper investigates the role of polymeric liners on hydrogen permeation behavior using finite element modeling. For this, a UMATHT subroutine is developed within the Abaqus software to implement a new hydrogen permeation transport model with extended governing equations. Through the simulations and material modeling, the role of hydrogen transport properties (permeability, diffusivity, and solubility), structural characteristics (crystallinity, free volume, thickness) of plastic liners, and the role of operational parameters (concentration, pressure) are combined to validate the model from the experimental data in the literature to estimate the effective thickness required to maintain the permeation limit of the polymeric liner of 70 MPa Type IV COPVs.

Design of Type-IV Composite Pressure Vessel Based on Comparative Analysis of Numerical Methods for Modeling Type-III Vessels

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.