Investigation on mechanical behaviors under fatigue load of stacking sequences considering autofrettage process for highly reliable hydrogen storage vessel

Different stacking sequences of alternate and separate winding were designed to investigate the effects of various stacking sequences on the burst pressure of the hydrogen storage vessel under fatigue load considering autofrettage pressure. Based on the material parameters and the lay-up computed by netting theory, the WCM in Abaqus was introduced to create the model using metallic liner with 35 MPa working pressure, whose minimum design burst pressure was 82.25 MPa resulted from safety factor 2.35. The progressive damage model using Hashin failure criterion was created to predict the burst pressure with various stacking sequences. Four sets of typical schemes of alternate and separate winding were created and the stress levels of the composite layer were analyzed based on the modified Smith-Watson-Topper. Three typical stacking sequences were selected for winding and then hydraulic burst tests. The results showed that the alternate winding sequence was more favorable to the mechanical properties of the vessel. It was suggested that the stress fluctuated considerably from cylinder section to transition section in all stacking sequences and the concentrated winding scheme can lower the liner stress amplitude except being vulnerable to failure in the dome section. The results indicated that the alternate winding stacking sequence scheme with increasing helical angle can improve the burst pressure up to 104.4 MPa, whereby the corresponding numerical error is 5.6 %.