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To improve the fatigue performance of high-pressure hydrogen storage vessels, a method is proposed to determine the optimal autofrettage pressure of the vessel using numerical simulation and experimental verification. First, a finite element model considering the actual structure of the vessel is established based on grid theory. Then, the effect of autofrettage pressure on the equivalent alternating stress amplitude of liner under cyclic fatigue load is studied by using the modified equation of Smith-Watson-Topper mean stress. Lastly, the optimum autofrettage pressure is determined according to the DOT-CFFC and CGH2R standards, and the fatigue life is predicted. The results show that under the optimum autofrettage pressure, the bearing capacity of the liner under working pressure and the fatigue life under fatigue cycle load are increased by 74% and 12 times, respectively. The experimental results are in good agreement with the numerical simulation results, with an average error of 6.3%. This research has important reference significance for the preliminary design stage of composite vessels. [ABSTRACT FROM AUTHOR]

A fatigue life prediction method is developed for the high-pressure hydrogen storage vessel based on theoretical research and experimental verification. Firstly, the finite element model of vessel was built considering wound angle of head, thickness and number of the composite layer, then simulation was performed. The optimum range of autofrettage pressure was obtained by FEA with consideration of the DOT-CFFC and CGH2R standards. The influence of autofrettage pressure, metal liner thickness, and fiber thickness on vessel fatigue life was discussed under internal pressure cyclic load. Finally, the experimental verification was carried out. It was found that fatigue failure first occurred in middle cylinder. The experiment results agree well with theory analysis. Their average error is 6.33%. • The optimum range of autofrettage pressure for high-pressure hydrogen storage vessel is obtained by simulation. • Fatigue life of high-pressure hydrogen storage vessel is predicted by theory and verified by experiment. • Influence of autofrettage pressure and liner thickness on fatigue life of vessel is analyzed. [ABSTRACT FROM AUTHOR]