An Integrated Systematic Approach to Linerless Composite Tank Development

Mallick, Kaushik; Cronin, J. Scott; Ryan, Kevin; Arzberger, Steven; Munshi, N. A.; Paul, Chris; Welsh, Jeffry S.

doi:10.2514/6.2005-2089

Cited by 32 publications

(24 citation statements)

References 11 publications

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“…Specifically, this model relates microcrack density to the global constitutive response (e.g., elastic modulus) and the material microcrack fracture toughness. As derived by Nairn, the microcracking energy release rate, ∆G m , due to the formation of new microcracks under a uniaxial cyclic load of ∆σ in a cross-ply laminate is: 3,19 …”

Section: Analytical Modelingmentioning

confidence: 99%

“…Since a cross-ply laminate is the building lock of essentially all laminate architectures for linerless composite tanks, 3 tank designers can use this analytical model to optimize the tank design to maximize the amount of cycles before microcracking and leakage occurs. The model predicts how microcracks in the transverse (i.e., 90º) ply of the unit cell evolve as a function of cyclic loads.…”

Section: Analytical Modelingmentioning

confidence: 99%

“…CTD-7.1 is a highly toughened matrix system developed by CTD that has shown significant resistance to microcrack formation under static mechanical load. 3 In addition it has a low viscosity and long working time suitable for wet filament winding of linerless composite tanks. The goal of the current work is to investigate how this composite material system performs under cyclic mechanical loading.…”

Section: A Selection Of Materials Systemmentioning

confidence: 99%

“…Since the cylindrical section of a filament-wound composite tank consists of interspersed layers of hoop and helical plies subjected to a biaxial stress state, a cross-ply laminate of [0/90] s construction can be considered to be a building block for damage (microcrack) analysis of the tank. 3 The constants, A and n, of the analytical model of damage growth are material constants and can now be used to predict the damage growth in a cross-ply laminate with ply thickness representing the tank wall.…”

Section: Illustrative Examplementioning

confidence: 99%

“…Success in developing these new tanks will hinge on success in developing new, toughened resin materials that are specially tailored for the applications, and new analysis tools and test protocols that can verify the new materials meet both the macro-scale and the micro-scale requirements. 3 Numerous research efforts in the past have focused on models to predict the fatigue life of composite materials based on the failure stress vs. cycles (S-N) curves of the material. [4][5][6][7][8] Several studies have also focused on phenomenological models, based on continuum damage mechanics, to predict residual stiffness/strength of composites subjected to cyclic load.…”

Section: B Designing Linerless Composite Tanks To Minimize Permeationmentioning

confidence: 99%

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Prediction of Pressure Cycle Induced Microcrack Damage in Linerless Composite Tanks

Ryan¹,

Cronin²,

Arzberger³

et al. 2006

47th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials ConferenceSelf Cite

3
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4
0

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The public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information AFRL-ML-WP-TP-2006-435 DISTRIBUTION/AVAILABILITY STATEMENTApproved for public release; distribution is unlimited. SUPPLEMENTARY NOTES ABSTRACTLinerless composite tanks made from continuous carbon fiber reinforced polymers will enable significant mass and cost savings over lined, composite overwrapped tanks. The key technical challenge in developing these linerless tanks will be to choose and/or design the material to resist microcracks that may lead to leakage. Microcracks are known to form in the matrix of a composite due to mechanical stresses transverse to the reinforcing fiber direction. This paper presents an approach for characterizing the accumulation of microcracks in linerless composite tank materials under cyclic mechanical loading associated with multiple fill-and-drain pressure cycles. The model assumes that the rate of microcrack-damage accumulation is related to the microcracking fracture toughness of the material through a modified Paris-law formulation. A key artifact of this model is that microcrack-damage accumulation under cyclic load can be predicted from only two material constants. This damage accumulation model is validated through a series of coupon tests, and an illustrative example is presented to demonstrate how the model can be used to predict the microcracking performance of a linerless composite tank subjected to fatigue cycles. SUBJECT TERMS Air Force Research Laboratory (AFRL/VSSV), Kirtland AFB, NM 87117-5776Linerless composite tanks made from continuous carbon fiber reinforced polymers will enable significant mass and cost savings over lined, composite overwrapped tanks. The key technical challenge in developing these linerless tanks will be to choose and/or design the material to resist microcracks that may lead to leakage. Microcracks are known to form in the matrix of a composite due to mechanical stresses transverse to the reinforcing fiber direction. This paper presents an approach for characterizing the accumulation of microcracks in linerless composite tank materials under cyclic mechanical loading associated with multiple fill-and-drain pressure cycles. The model assumes that the rate of microcrack-damage accumulation is related to the microcracking fracture toughness of the material through a modified Paris-law formulation. A key artifact of this model is that microcrack-damage accumulation under cyclic load can be predicted from only two material constants. This damage accumulation model is validated through a seri...

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Section: Analytical Modelingmentioning
confidence: 99%

Section: A Selection Of Materials Systemmentioning
confidence: 99%

Section: Illustrative Examplementioning
confidence: 99%

Section: B Designing Linerless Composite Tanks To Minimize Permeationmentioning
confidence: 99%

See 3 more Smart Citations
Prediction of Pressure Cycle Induced Microcrack Damage in Linerless Composite Tanks
Ryan¹,
Cronin²,
Arzberger³
et al. 2006
47th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials ConferenceSelf Cite
3
0
4
0
View full text Add to dashboard Cite
The public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information AFRL-ML-WP-TP-2006-435 DISTRIBUTION/AVAILABILITY STATEMENTApproved for public release; distribution is unlimited. SUPPLEMENTARY NOTES ABSTRACTLinerless composite tanks made from continuous carbon fiber reinforced polymers will enable significant mass and cost savings over lined, composite overwrapped tanks. The key technical challenge in developing these linerless tanks will be to choose and/or design the material to resist microcracks that may lead to leakage. Microcracks are known to form in the matrix of a composite due to mechanical stresses transverse to the reinforcing fiber direction. This paper presents an approach for characterizing the accumulation of microcracks in linerless composite tank materials under cyclic mechanical loading associated with multiple fill-and-drain pressure cycles. The model assumes that the rate of microcrack-damage accumulation is related to the microcracking fracture toughness of the material through a modified Paris-law formulation. A key artifact of this model is that microcrack-damage accumulation under cyclic load can be predicted from only two material constants. This damage accumulation model is validated through a series of coupon tests, and an illustrative example is presented to demonstrate how the model can be used to predict the microcracking performance of a linerless composite tank subjected to fatigue cycles. SUBJECT TERMS Air Force Research Laboratory (AFRL/VSSV), Kirtland AFB, NM 87117-5776Linerless composite tanks made from continuous carbon fiber reinforced polymers will enable significant mass and cost savings over lined, composite overwrapped tanks. The key technical challenge in developing these linerless tanks will be to choose and/or design the material to resist microcracks that may lead to leakage. Microcracks are known to form in the matrix of a composite due to mechanical stresses transverse to the reinforcing fiber direction. This paper presents an approach for characterizing the accumulation of microcracks in linerless composite tank materials under cyclic mechanical loading associated with multiple fill-and-drain pressure cycles. The model assumes that the rate of microcrack-damage accumulation is related to the microcracking fracture toughness of the material through a modified Paris-law formulation. A key artifact of this model is that microcrack-damage accumulation under cyclic load can be predicted from only two material constants. This damage accumulation model is validated through a seri...
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Microcrack Resistant Polymers Enabling Lightweight Composite Hydrogen Storage Vessels
Mallick
¹
,
Cronin
²
,
Fabian
³

et al. 2010
Ceramic Transactions Series
Self Cite
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1
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Robust, lightweight, storage vessels are needed for on-board storage of hydrogen. Challenges with currently used composite overwrapped vessels include weight due to the non-load bearing liner, performance reliability resulting from separation of the liner, and costs of extra manufacturing steps to fabricate the liner. Linerless composite vessels, where the composite shell serves both as a permeation barrier and a structure, can provide for the lightest weight vessels for a given set of requirements. Preliminary designs show up to 25% weight savings allowing reduced storage system mass and more internal volume. These tanks are targeted to attain hydrogen mass storage efficiency of 15-18% as compared to 3-4% from lined vessels. Manufacturing cost, operational risks and maintenance costs can be reduced due to inherently simple construction. Engineering methods that define material performance requirements, such as polymer strain requirements in a lamina have been used to guide the development of microcrack resistant polymers. Performance of linerless composite tanks has been demonstrated and qualification is on-going. INTRODUCTIONHydrogen is an ideal energy carrier that can help increase our energy diversity and security by reducing our dependence on hydrocarbon-based fuels. Hydrogen can be produced from domestic resources that are clean, diverse, and abundant; fuel cells provide a technology to use this energy in a highly efficient way, in numerous applications, with only water and heat as byproducts. The US Department of Energy's initiative and push has already put fuel cell buses on the road, and may soon put new fuel-cell powered vehicles on the nation's rails and waterways.

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Service load analysis and ply stacking optimization for composite tool of aerospace cryogenic tank
Guan,
Chi,
Zhan
et al. 2024
Polymer Composites
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The integrated manufacturing of aerospace composite cryogenic tanks is crucial for enhancing payload efficiency, reducing costs, and leading the aerospace industry upgrade. Composite segmented tool, which balances internal support and mold surface, must not only meet the requirements of disassembly and demolding but also ensure sufficient stiffness without deformation under loads like winding tension and curing shrinkage during tank formation. This article addresses the challenge faced by composite tool with uniformly thick ply stacking schemes, where the weight increases significantly with the rocket body diameter, rendering functions such as disassembly and demolding unfeasible. A global–local optimization approach aimed at achieving variable‐thickness ply stacking designs for composite tooling was proposed. Starting with a defined segmented tool design for the Φ3.35 m tank, models for calculating winding tension under complex service conditions and finite element models for curing shrinkage were established. Optimization of ply shapes, dimensions, and sequences using OptiStruct was conducted, which achieved a weight reduction of 34.48% while ensuring that deformations under loading met design standards. Subsequently, the engineering trials for the composite melon petal and wallboard corresponding to the Φ600 mm tank were conducted based on the optimized scheme. The maximum deformations for the two components were 0.43 mm and 0.15 mm, respectively, meeting the manufacturing requirements for engineering applications. The results provide a lightweight, high‐stiffness, and detachable tool design scheme for achieving the integrated manufacturing of extra‐large (Φ10 m) composite tanks.Highlights The external load was analyzed through theoretical and simulation approaches. The weight of composite tool was significantly reduced after optimization. The engineering prototypes of the segmented tools were achieved.

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An Integrated Systematic Approach to Linerless Composite Tank Development

Cited by 32 publications

References 11 publications

Prediction of Pressure Cycle Induced Microcrack Damage in Linerless Composite Tanks

Prediction of Pressure Cycle Induced Microcrack Damage in Linerless Composite Tanks

Microcrack Resistant Polymers Enabling Lightweight Composite Hydrogen Storage Vessels

Service load analysis and ply stacking optimization for composite tool of aerospace cryogenic tank

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