Smart glass fiber hydrogen tank for high pressure: design and sensor-based analysis

This study presents the experimental design and performance evaluation of a cost-effective Type IV hydrogen storage tank reinforced with glass fiber/epoxy composite. The tank, with a 6 mm-thick composite wall and 10 MPa working pressure, achieved a burst pressure of 35.7 MPa, significantly higher than previously reported values for similar E-glass vessels, demonstrating the effectiveness of a novel 15°/90°/30°/20°/90°/90° stacking sequence. Strain monitoring was conducted using both Fiber Bragg Grating (FBG) and Distributed Fiber Optic Sensors (DFOS), revealing highly consistent strain evolution and linear pressure-strain behavior up to 15 MPa. DFOS offered higher spatial resolution (0.65 mm) and broader coverage than FBG (10 mm gauge length), enabling detailed mapping of localized strain variations. Microtomography identified fiber misalignment and delamination post-burst, underscoring the need for filament winding optimization. This study is the first to directly compare DFOS and FBG in a composite pressure vessel, confirming DFOS as a powerful tool for full-field structural health monitoring in hydrogen storage systems. • Designed glass fiber/epoxy vessel for hydrogen with 10 MPa working pressure. • Direct comparison of fiber Bragg grating and distributed fiber sensors. • Innovative 15°/90°/30°/20°/90°/90° stacking sequence enhanced pressure resistance. • Distributed fiber sensors enabled high-resolution strain mapping on the vessel. • Microtomography imaging enhanced quality control and defect detection.