A literature review of failure prediction and analysis methods for composite high-pressure hydrogen storage tanks

With the development of hydrogen fuel cell vehicles, the on-board hydrogen storage technology with safety, efficiency and economy has become a fundamental part. Low cost, light weight and good safety performance are required for the on-board hydrogen storage tanks. The composite high-pressure hydrogen storage tank has been recognized as an efficient solution that could address these problems. However, the complex working environment of hydrogen-thermo-mechanism presents challenge to the failure analysis and predictive model establishment of the composite hydrogen storage tanks. The crucial parameters or indicators for tank's failure analysis include burst pressure, damage state and fatigue lifetime, etc. So this paper gives a comprehensive review on the failure behavior analysis methods and prediction models of composite high-pressure hydrogen storage tanks from the literature. First, the failure analysis methods of composite high-pressure hydrogen storage tanks are summarized. Second, the latest literature regarding failure mode predictive methods and models of type III and type IV tanks are reviewed. The different failure criteria are compared and summarized, including some new failure criteria. These criteria enable failure analysis methods to obtain the interaction information on the interaction between the microscopic and macroscopic aspects of the composite. Damage evolution model and constitutive model are summarized. The post-initial failure behavior of the composite laminates structure is simulated by the material property degradation method (MPDM), especially the continuum damage mechanics (CDM) in conjunction with commercial finite element (FE) analysis method. The process of progressive failure analysis of composite tank is summarized as a reference for subsequent failure analysis. The future work of progressive failure analysis should focus on the initial failure of the composite material and microscopic failure mechanisms. The burst, fiber damage and fatigue life are the mainly investigated failure modes for type III composite hydrogen storage tank. For Type IV, the mainly researched failure modes are the collapse and blistering of the liner, burst and damage. The different finite element analysis methods and failure predictive models were classified and summarized. Further improvements were required for the simulation models of full-scale structure of the tank in the working environment or under the complex fiber winding modes. The liner of the type IV cylinder is completely distinct from that of the type III, therefore the behavior of collapse and blistering of the liner needs to be further investigated. The factors that affect collapse and blistering should be explored. The future research need focus on controlling these factors and monitoring the effects of these factors towards structural strength.