Yitao Liu

As a commonly used liner material for fully reinforced, carbon-fiber-composite hydrogen storage cylinders, polyamide 6 (PA6) needs to meet the required hydrogen permeation index during use; otherwise, it may adversely affect the safe use of hydrogen storage cylinders. The hydrogen permeability of PA6 under different temperatures and pressures was tested, and the variations in its hydrogen permeability were investigated. Additionally, the hydrogen permeability of PA6, polyamide 11 (PA11), and high-density polyethylene (HDPE) at a temperature of 288 K and a pressure of 70 MPa was tested, and the differences in hydrogen permeability among these commonly used liner materials for type IV on-board hydrogen storage cylinders were studied. The results reported herein indicate that both the hydrogen permeability and diffusion coefficient of PA6 increase with rising test temperature but decrease with increasing pressure. The solubility coefficient of PA6 shows no significant change with varying test temperatures and pressures. At a test temperature of 288 K and a pressure of 70 MPa, among the three materials, PA6 has slightly stronger hydrogen permeation resistance than PA11, while HDPE has the least resistance. These research findings can serve as valuable reference data for evaluating the hydrogen permeability of liner materials.

This study investigates the sealing performance of a combined sealing structure under extremely high and low temperature conditions, considering potential issues like high-temperature aging and low-temperature brittle fracture, which can lead to sealing failure. EPDM rubber underwent uniaxial compression tests at high, low, and normal temperatures, then the sealing performance under extreme working conditions was compared with that under normal temperature conditions. Additionally, the influences of gasket parameters and gas pressure on the sealing performance were analyzed. The result shows that compared with the normal temperature conditions, the maximum von Mises stress is reduced by 65% and the effective sealing length and the maximum contact pressure is reduced by 40% under the high temperature conditions, while the maximum von Mises stress is increased by 7 times and the maximum contact pressure is increased by a remarkable 7 times under the low temperature conditions. In the range of 10–100 MPa, the increase in gas pressure aggravates the O-ring stress concentration and improves the sealing performance relatively. When the thickness of gasket is 0.85–1.05 mm, the stress concentration of the O-ring is lighter and the sealing performance is better.

Type IV hydrogen storage cylinders comprise a polymer liner and offer advantages such as lightweight construction, high hydrogen storage density, and good fatigue performance. However, they are also characterized by higher hydrogen permeability. Consequently, it is crucial for the polymer liner material to exhibit excellent resistance to hydrogen permeation. International organizations have established relevant standards mandating hydrogen permeation tests for the liner material of type IV on-board hydrogen storage cylinders. This paper provides a comprehensive review of existing research on hydrogen permeability and the hydrogen permeation test methods for the polymer liner material of type IV on-board hydrogen storage cylinders. By delving into the hydrogen permeation mechanism, a better understanding can be gained, offering valuable references for subsequent researchers in this field. This paper starts by thoroughly discussing the hydrogen permeation mechanism of the liner material. It then proceeds to compare and analyze the hydrogen permeation test methods specified by various standards. These comparisons encompass sample preparation, sample pretreatment, test device, test temperature and pressure, and qualification indicators. Then, this study offers recommendations aimed at enhancing the hydrogen permeation test method for the liner material. Additionally, the influence of test temperature, test pressure, and polymer material properties on the hydrogen permeability of the liner material is discussed. Finally, the influences of the test temperature, test pressure, and polymer material properties on the hydrogen permeability of the liner material are discussed. Future research direction on the hydrogen permeability and hydrogen permeation test method of the liner material of the type IV hydrogen storage cylinder has been prospected.

The liner of a carbon fiber fully reinforced composite tank with thermoplastic liner (type IV) works in a hydrogen environment with varying temperature and pressure profiles. The ageing performance of the thermoplastic liner may affect hydrogen permeability and the consequent storage capacity, degrade the mechanical properties, and even increase the leakage risks of type IV tanks. In this paper, both testing procedures and evaluation parameters of an ageing test in a hydrogen environment required in several standards are compared and analyzed. Hydrogen static exposure in a high-temperature condition with a constant temperature and pressure is suggested to be a reasonable way to accelerate the ageing reaction of thermoplastic materials. A total of 192 h is considered a superior ageing test duration to balance the test economy and safety. The ageing test temperature in the high-temperature condition is suggested as no lower than 85 °C, while the upper limit of test pressure is suggested to be 1.25 NWP. In addition, the hydrogen permeation coefficient and mechanical properties are recognized as important parameters in ageing performance evaluation. Considering the actual service conditions, the influence of temperature/pressure cycling, depressurization rate, and humidity on the ageing performance of thermoplastics in hydrogen are advised to be investigated experimentally.