Characterizing the effects of liner and fiber-reinforced resin composite shell on fracture energy in type-III high-pressure composite tanks

The increasing adoption of fuel-cell vehicles, driven by their environmentally friendly zero-emission features, is a crucial step towards reducing environmental damage. However, current research primarily focuses on stress-related aspects of pressurized tanks, leaving a critical knowledge gap regarding potential fractures within the tank’s body, which can accelerate pressure tank failure. This study aims to address this concern by analyzing alternative fiber materials beyond carbon fiber in a finite element analysis model, with the primary objective of enhancing the durability of pressurized tanks for hydrogen-fueled vehicles against fracture loading. The investigation revolves around the fracture behavior of type-III high-pressure composite tanks, pivotal components for the secure operation of hydrogen-powered fuel cell vehicles. Various configurations of Al6061 and Al7178 liners coupled with six distinct fiber materials and six different winding orientations [(± 15/90)n]T, (± 30/90)n, [(± 45/90)n]T, [(± 55/90)n]T, [(± 60/90)n]T, and [(± 75/90)n]T have been meticulously assessed to provide an in-depth analysis of fracture energy behavior in composite tanks. The stress intensity factor (GI) was computed using a compact tension model developed in Abaqus, for all composite variations under consistent conditions, providing a robust foundation for understanding the fracture behavior. Additionally, MATLAB was utilized to calculate the effective elastic modulus for the selected composite materials. Subsequently, the strain energy release rate was derived from the relationship between the GI and the effective elastic modulus of composite tanks. The derived GI revealed notable improvements in fracture resistance for specific composite shells and liner materials, particularly at higher winding orientations. The results emphasized the superior performance of boron-epoxy composite shells for type-III pressure vessels, exhibiting the lowest GI values and exceptional crack resistance. Notably, Al7178 combined with boron-epoxy outperformed Al6061 composites at higher winding orientations, while glass–epoxy shells exhibited greater susceptibility to crack propagation, especially in specific ply orientations.