Seamless Hydrogen Pressure Vessel Using Flow Formed Composite
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Solution Overview
Problem
Current hydrogen storage pressure vessels face challenges in withstanding high pressures and pressure fluctuations, temperature variations, mechanical loading, and hydrogen embrittlement, while also requiring cost-effective and lightweight designs that can resist external damage and complex containment issues.
Innovation Solution
A seamless pressure vessel is produced using a multi-layer composite sheet metal material with a carrier layer of carbon steel and a hydrogen-resistant shielding layer, formed through flow forming, and reinforced with fibers, which is heat-treated and encapsulated with thermosetting plastic to achieve enhanced mechanical strength and resistance to embrittlement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If internal pressure is increased to minimize storage space, then hydrogen storage density is improved, but mechanical stability demands increase
Solution Approach 1:
The pressure vessel uses a composite structure consisting of an inner layer made of high-grade steel alloy and an outer layer made of carbon steel or low-alloyed steel. This multi-layer composite design allows the vessel to withstand the high internal pressures required for dense hydrogen storage while maintaining mechanical stability through the combined properties of different steel grades.
2Object-affected harmful factors
If conventional surface coating is applied to protect from hydrogen embrittlement, then initial protection is achieved, but permanent prevention fails
Solution Approach 1:
The vessel employs a composite structure with an inner layer of high-grade steel alloy that inherently resists hydrogen embrittlement, combined with an outer layer of carbon steel or low-alloyed steel. This multi-layer composite design provides permanent protection against hydrogen embrittlement through the synergistic properties of different steel grades, rather than relying on conventional surface coatings that fail over time.
3Object-affected harmful factors
If multi-layer composite material is used to resist hydrogen embrittlement, then protection is improved, but manufacturing complexity increases
Solution Approach 1:
The pressure vessel is manufactured by segmenting the multi-layer composite sheet metal material into a carrier layer made of steel material and a shielding layer resistant to hydrogen embrittlement. This segmentation allows each layer to be optimized for its specific function while simplifying the overall manufacturing process through the use of pre-fabricated composite materials.
Solution Approach 2:
The pressure vessel utilizes a multi-layer composite sheet metal material comprising a carrier layer made of steel material and a shielding layer resistant to hydrogen embrittlement. This composite material approach provides inherent protection against hydrogen embrittlement while maintaining manufacturing efficiency through integrated material design.
4Weight of moving object
If lightweight design is implemented, then cost-effectiveness is improved, but resistance to external mechanical loading decreases
Solution Approach 1:
The pressure vessel employs a composite structure with an inner layer of high-grade steel alloy and an outer layer of carbon steel or low-alloyed steel. This multi-layer composite design optimizes the weight-to-strength ratio, providing adequate resistance to external mechanical loading while maintaining lightweight characteristics for cost-effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in lightweight, cost-effective pressure vessels that withstand high internal pressures, pressure fluctuations, and mechanical loading, while preventing hydrogen embrittlement and external damage, allowing for efficient hydrogen storage with improved safety and durability.
Implementation Method 1
forming a round or tubular workpiece consisting of a multi-layer composite sheet metal material by a flow forming process into a seamless hollow body
Implementation Method 2
The seamless hollow body produced in this way is subjected to heat treatment and/or reinforcement with fibers
Data Source
AI summary
A method may be used to produce a seamless pressure vessel for storing hydrogen. So that such a pressure vessel withstands both very high internal pressures and pressure fluctuations and (low) temperatures and temperature fluctuations and also high mechanical loading, is resistant to embrittlement, and is comparatively lightweight, a round or tubular workpiece may be formed that includes a multi-layer composite sheet metal material comprising a carrier layer made of steel material and a shielding layer resistant to hydrogen embrittlement by a flow forming process into a seamless hollow body, which serves as a semifinished product to be further processed into the seamless pressure vessel. The shielding layer may represent an inner layer of the pressure vessel. During the flow forming of the workpiece, the shielding layer may be retained as a whole-area, uninterrupted layer.