Analysis on failure test and evaluation about refueling receptacle of onboard hydrogen system

As the key component of the onboard hydrogen system, the service life and failure problem of the refueling receptacle easily leads to the hydrogen leakage accident which give rise to the suffocation, the frostbite, the burns, and the impact injuries. The typical hydrogen leakage accidents include the accidental leakage, the ignition, the deflagration, and the explosion. Therefore, the failure test and evaluation problem about the refueling receptacle is focused on. In this paper, the failure test and evaluation about the refueling receptacle covering the vibration resistance performance, the temperature resistance performance, and the durability was studied. First, the failure mechanisms of the refueling receptacle involving the vibration, the temperature, and the durability based on the vehicle operating conditions were clarified. Second, according to the test experience and the vehicle operating condition, the test methods about the failure phenomenon of the refueling receptacle were established, respectively. Finally, the failure test results of the refueling receptacle were analyzed. The failure of the refueling receptacle may caused by the aging and failure of sealing element, the metal creep aging and material damage, the decline in the contact stress at the low-temperature connection, the loose connection, and the internal structural ectopia.