Prediction and optimization of failures in high-pressure hydrogen storage vessels: A review

The prediction and optimization of typical failures are critical for ensuring the safety and reliability of composite high-pressure hydrogen storage vessels, which are pivotal in hydrogen fuel cell vehicles due to their lightweight, high efficiency, and portability. The review systematically examines the failure behaviors, with a particular focus on burst failure and fatigue failure, which directly influence structure strength and vessel lifespan. It first discusses failure criteria for fiber-reinforced composites, and then failure evaluation models based on these criteria are summarized, which contribute to determining burst and fatigue failures. The application of finite element methods (FEM) in progressive damage analysis and structural prediction is discussed, highlighting their role in failure assessment. Additionally, optimization strategies for liners, composite layers, and winding techniques are reviewed, aiming to enhance failure resistance. Notably, a multi-filament winding technique is presented, addressing issues like fiber crossing and sagging, improving vessel load-bearing performance, reducing fiber usage, and boosting efficiency. • Studies on failure behaviors of high-pressure hydrogen storage vessels have been reviewed. • Existing methods for predicting burst pressure and fatigue life have been systematically categorized. • Various approaches for optimizing liners, composite layers, and filament winding technique have been summarized. • A novel winding technique called multi-filament winding has been introduced firstly. • Research trends and future opportunities are identified.