Manufacturing Challenges in Advanced Cylindrical Composite Pressure Vessels for Hydrogen Storage: A Comprehensive Review

Abstract

Advances in cylindrical high-end hydrogen storage systems for aerospace, undersea vacuum enclosures, and automobiles use Type V composite pressure vessels (CPV) as the next generation of sustainable energy storage. The latest liner-less CPV (Type V) is most challenging. The basic need of this manufacturing aspect review on CPV is the transition toward a more sustainable hydrogen energy storage system. As analyzed through our review that Type IV pressure vessels optimized with this transition to Type V, where weight reduction is up to > 25%, higher load-bearing efficiency is reported in past studies for Type V in comparison to Type IV vessels, with increase in volumetric density up to > 15% and more, and most importantly, hydrogen barrier performance as permeability is reduced from 10⁻¹² to < 10⁻¹⁶ mol m⁻¹ s⁻¹ Pa⁻¹ addressed. Type V pressure vessels eliminate the polymer liner, causing nonuniform stresses, which hinders in Type III/IV COPVs. This results in more uniform stress distribution and high burst performance at reduced mass. Studies show higher burst pressure and improved structural efficiency. At cryogenic CcH₂ hydrogen storage of up to 35 MPa pressure with improved epoxies is also explored. Mechanical characteristics of cross-linked composite laminates, including thin films of clay, sand, polyethylene, and polyurethane, were also analyzed in the CcH₂ storage system. Strengthening (Type IV) composite pressure vessels with proper fiber/matrix alignment and polyethylene films instead of a polyethylene liner causes embrittlement and failure due to composite and plastic ties. Various stacking sequences related to flaws have been explored, Type IV (plastic liner) composite pressure vessels for improvement in Type V CPV. Filament winding techniques and automated fiber placements (AFP) used for winding sequence and stacking geometries of helical, hoop, and polar composite winding layers reveal that at 55° helical, followed by hoop winding, provides the highest strength. Based on our comprehensive review, we found that the fabrication and permeability challenges of liner-less (Type V) vessels need further study. While recent advances in materials (e.g., high-performance resins, nanoparticle reinforcement) and manufacturing techniques (e.g., AFP, out-of-autoclave curing) show promise, consistent and scalable solutions to address hydrogen permeation and structural integrity in liner-less designs are still under active investigation.