A review of toroidal composite pressure vessel optimisation and damage tolerant design for high pressure gaseous fuel storage

Abstract

On-board high-pressure storage of hydrogen gas and compressed natural gas is critical to the widespread adoption of alternative gaseous fuel to reduce CO 2 emissions in transportation. Cylindrical pressure vessels are the traditional option for on-board gaseous fuel storage; however they possess domed heads that are prone to over-design and a source of manufacturing difficulties. Toroidal composite pressure vessels (CPV) have been recognised as a volumetrically efficient solution that could address these problems, thus reducing vessel mass, while improving storage efficiencies. Currently, there exist many gaps in toroidal CPV research which must be addressed to fully realise the potential of this technology. Herein we present a comprehensive and critical review of the design and optimisation of toroidal CPVs, focusing on damage tolerant design as a key requirement to meet safety standards and optimisation of toroidal cross-sectional profiles (shape, thickness variation and fibre winding pattern) to reduce or eliminate stress non-uniformity. An original analysis of toroidal radius ratio (R/r) influence on the thickness profiles of naturally-thickened and isotensoid circular toroidal CPVs is conducted. It is concluded that a focus on smaller radius ratios (1.25 < R/r < 3) is required to maximise the potential spacesaving and volumetric efficiencies of the torus. Leading international CPV standards are analysed in order to adapt three important design qualification requirements from cylindrical to toroidal structures. Building block approaches are also presented to aid the damage tolerant design of toroidal CPVs for the relevant design qualification tests.

Stress–strain and burst failure analysis of fiber wound composite material high-pressure vessel

“…At present, many researchers have made lots of studies on the design of composite gas cylinders. 4 Park et al 5 used ANSYS program to establish a composite gas cylinder model by calculating the parameters such as the thickness, angle and number of layers of the composite layer, and then the distribution law of the stress and strain of the gas cylinder was obtained. Antunes et al 6 developed a parametric analysis of the composite hydrogen vessel based on the improved classical composite stacking theory and composite micromechanics.…”

Fabrication of High-Quality Polymer Composite Frame by a New Method of Fiber Winding Process

“…Damage phenomena in normal composite structures (with uniform, homogeneous, and consistent fiber arrangement) under loading normally initiate with micro-scale matrix cracking/crushing that grow in size across the ply thickness (parallel to the fibers), and induce early stage of multi-delamination event. Further loading could result in local fiber cracking/buckling, excessive multiple intra-and inter-laminar failures, weaken the laminate and lead to structural rupture [13,[51][52][53][54]. The fiber arrangement in normal composites would result the fibers as the load-bearing core component of the composite, to sustain the load, and ensure the composite frame to bear the designed load before fracture.…”

“…Polymer composite frames are mainly used to reinforce the chassis, body, and doors of a car, or to strengthen the fuselage and attach windows to the fuselage, etc., in the aerospace and automotive industries, as well as in the manufacture of agricultural machinery [3][4][5][6]. These composite frames are primarily used due to their excellent mechanical and physical properties such as resistance to harsh weather conditions, as well as long term resistance to corrosion in severe environmental conditions, the wound fibers (usually carbon, aramid, or glass fibers) and the fabrication process [11][12][13]. Ensuring the correct fiber winding angles from the geometric point of view and hence the homogeneity of the windings is one of the important aspects of composite quality.…”

Fabrication of High-Quality Straight-Line Polymer Composite Frame with Different Radius Parts Using Fiber Winding Process

“…Example of frame structures in the form of (left) pipe structure for oil and gas application, as well as (right) road and street light poles. Among many types of composite frame profiles, the cylindrical frame is frequently used in many applications due to its higher mechanical toughness, and also easier manufacturing process [1,9,10,24,31]. In this regard, new investigations to advance the production technology of frame with complex profile geometries led to the design of the high-quality frame with 3D cylindrical straight and curved shapes [1,[32][33][34].…”