Design, Analysis, and Testing of a Type V Composite Pressure Vessel for Hydrogen Storage

Hydrogen, as a zero-emission fuel, produces only water when used in fuel cells, making it a vital contributor to reducing greenhouse gas emissions across industries like transportation, energy, and manufacturing. Efficient hydrogen storage requires lightweight, high-strength vessels capable of withstanding high pressures to ensure the safe and reliable delivery of clean energy for various applications. Type V composite pressure vessels (CPVs) have emerged as a preferred solution due to their superior properties, thus this study aims to predict the performance of a Type V CPV by developing its numerical model and calculating numerical burst pressure (NBP). For the validation of the numerical model, a Hydraulic Burst Pressure test is conducted to determine the experimental burst pressure (EBP). The comparative study between NBP and EBP shows that the numerical model provides an accurate prediction of the vessel’s performance under pressure, including the identification of failure locations. These findings highlight the potential of the numerical model to streamline the development process, reduce costs, and accelerate the production of CPVs that are manufactured by prepreg hand layup process (PHLP), using carbon fiber/epoxy resin prepreg material.