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<p>Safe and efficient hydrogen storage is a critical challenge for the widespread adoption of hydrogen as a clean energy carrier. This work presents a comprehensive multiphysics investigation into the design and optimization of Type III composite pressure vessels (CPVs). The study optimizes the fiber stacking sequence and winding angles of the composite shell using Ansys Composite Prep/Post (ACP), where different winding configurations are assessed against burst failure. The inverse reserve factor (IRF) is calculated from multiple failure criteria, including Tsai-Wu, Tsai-Hill, and Puck, to identify the optimal lay-up. The analysis identified the [902/60/-60]s sequence as the optimal configuration, achieving a maximum IRF of 0.97. The structural reliability of the optimal design is then further evaluated through fatigue life prediction, yielding a baseline mechanical life of 2.49 × 10^7 cycles, and modal analysis, which confirmed high dynamic stiffness preventing low-frequency resonance. Complementing the structural assessment, a 2D axisymmetric computational fluid dynamics (CFD) analysis using the Redlich-Kwong real gas model is performed to evaluate the effects of refueling parameters—mass flow rate, initial pressure, and ambient temperature—on internal temperature and gas velocity. The CFD results established critical thermal boundaries, demonstrating that mass flow rates exceeding 130&#xa0;g/s drive the system into an adiabatic heating regime, risking temperatures beyond the 85&#xa0;°C safety limit. By coupling detailed structural optimization with thermal-fluid dynamics, this integrated approach addresses a critical gap in existing research where these aspects are typically examined in isolation. The findings provide a holistic framework for designing safer, more reliable, and efficient hydrogen storage vessels tailored for practical refueling scenarios.</p>

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Structural and Thermal-Fluid Modeling of Type III Composite Pressure Vessel under Hydrogen Refueling Conditions

  • 期刊论文

  • 发表日期：

    2026年7月23日

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  • Reham Reda,
  • Yasmeen Khalifa

摘要

Safe and efficient hydrogen storage is a critical challenge for the widespread adoption of hydrogen as a clean energy carrier. This work presents a comprehensive multiphysics investigation into the design and optimization of Type III composite pressure vessels (CPVs). The study optimizes the fiber stacking sequence and winding angles of the composite shell using Ansys Composite Prep/Post (ACP), where different winding configurations are assessed against burst failure. The inverse reserve factor (IRF) is calculated from multiple failure criteria, including Tsai-Wu, Tsai-Hill, and Puck, to identify the optimal lay-up. The analysis identified the [902/60/-60]s sequence as the optimal configuration, achieving a maximum IRF of 0.97. The structural reliability of the optimal design is then further evaluated through fatigue life prediction, yielding a baseline mechanical life of 2.49 × 10^7 cycles, and modal analysis, which confirmed high dynamic stiffness preventing low-frequency resonance. Complementing the structural assessment, a 2D axisymmetric computational fluid dynamics (CFD) analysis using the Redlich-Kwong real gas model is performed to evaluate the effects of refueling parameters—mass flow rate, initial pressure, and ambient temperature—on internal temperature and gas velocity. The CFD results established critical thermal boundaries, demonstrating that mass flow rates exceeding 130 g/s drive the system into an adiabatic heating regime, risking temperatures beyond the 85 °C safety limit. By coupling detailed structural optimization with thermal-fluid dynamics, this integrated approach addresses a critical gap in existing research where these aspects are typically examined in isolation. The findings provide a holistic framework for designing safer, more reliable, and efficient hydrogen storage vessels tailored for practical refueling scenarios.