Advances in failure assessment of Type IV hydrogen storage vessels: A critical review

The growing demand for hydrogen energy underscores the need for reliable storage systems, with Type IV hydrogen storage vessels emerging as a leading technology due to their lightweight, exceptional durability, and high energy storage density. This review critically examines recent advances in the failure assessment of Type IV vessels, focusing on material behaviors, design considerations, failure modes, and reliability evaluation methods. First, the discussion begins with an overview of hydrogen storage systems, emphasizing the evolution of Type IV vessels and key design factors influencing their failure resistance, including material selection criteria and compliance with regulatory standards. Next, a detailed analysis of failure mechanisms in polymer liners and carbon fiber-reinforced polymer composites is presented, covering hydrogen permeation effects, mechanical degradation, and temperature-induced damage. The review highlights experimental and numerical techniques for characterizing and modelling these failure behaviors. Furthermore, various reliability assessment approaches-deterministic, uncertainty-based, and surrogate modeling-are evaluated for their effectiveness in predicting the lifespan of composite overwrapped pressure vessels. Despite significant progress, key challenges persist, including the accurate prediction of long-term performance under cyclic loading and extreme conditions. By consolidating key findings and identifying research gaps, this review proposes future directions to improve the safety and durability of Type IV hydrogen storage vessels, facilitating their broader adoption in sustainable energy systems.