In Situ Strain Monitoring of a Type IV Composite Hydrogen Storage Vessel Under Hydraulic Fatigue Using Embedded FBG Sensors

A 70 MPa Type IV hydrogen composite pressure vessel (CPV) was instrumented with embedded Fiber Bragg Grating (FBG) sensors to realize in situ strain monitoring during hydraulic fatigue cycles. FBG arrays were co-wound with carbon fibers during the filament winding process, forming an integrated multi-point sensing network within the composite layers. Hydraulic fatigue tests were conducted under pressure cycling between 2 MPa and 87.5 MPa, reaching 48,000 cycles. The embedded FBG sensors were able to stably record cyclic strain evolution with peak amplitudes of approximately 6000 με in the hoop layer and 3500 με in the helical layer under hydraulic cycling. The hoop layers exhibited gradually decreasing strain amplitudes from the inner to outer regions, while the helical layer maintained stable signal performance. Analysis of fiber survival times indicated that the FBGs embedded in helical layers remained functional throughout the entire test, confirming the long-term monitoring capability under high-pressure oil environments. This study demonstrates a practical embedded-sensing approach compatible with the filament-winding process, providing experimental support for fatigue-life evaluation and in-service safety monitoring of high-pressure hydrogen storage vessels.