16 Storhy Train-In Session 3 1 Cryoiii

Session 1.2: IntroductoryLectures

K. Hall

Session 3.2: Cryogenic Storage Systems

Dr. G. Bartlok

25th – 29th September 2006Ingolstadt

Session 3.2 Cryogenic Storage Systems G. Bartlok 2

3.1 Cryogenic Storage Systems

CV – Dr. G. Bartlok

Address:MAGNA STEYREngineeringLiebenauer Hauptstraße 3178041 Graz, AustriaEmail: [email protected]

Guido Bartlok, born 1970 in Frankfurt (Oder) in Germany, received his diploma in mechanical engineering at the Technical University Dresden. The Ph.D. work was done at the cryogenic institute of the TU Dresden. He joined the MAGNA STEYR Fahrzeugtechnik AG & Co KG in 2003. Mr. Bartlok is jointly responsibly for development of automotive liquid hydrogen storage systems and research activities (e.g. Project Management of the Subproject Cryogenic Storage within the EU 6th Framework Program IP “StorHy”).



Table of Content

• Overview of SP Cryogenic Storage

• Concepts & Requirements

• Material & Technology Development

• Proof of Feasibility

• Outer Jacket, Inner Tank, Lightweight Free-form Tank



Lectures on Liquid H2 Storage TechnologyDr. G. Bartlok, M. Bauer

Abstract:The SP Cryogenic Storage develops free-form lightweight tanks manufactured from composite materials as well as adequate production technologies. The cryogenic system will mainly consist of an outer jacket and an inner tank. A vacuum in between and applied multi layer insulation assures the cryogenic temperature in the inner tank. This extended lecture presents a selection of main topics and results reflecting the Subproject activities focused on cryogenic storage.


• Free-form geometry and automotive design

• Lightweight (e.g. composite) material properties

• Automotive production technologies

• Increased storage density

• Safety standards

• Reduced heat entry

• Recycling aspects

SP Cryogenic Storage – Objectives & Partners

Advanced Cryogenic Hydrogen Storage System:


Proof of Feasibility3 Cylindrical Tanks

Design &Requirements

„Free-form“ TankVirtual model

Start ofProject

2004 200720062005

Inner Tank

Outer Jacket& Inner Tank

Tests

SP Cryogenic Storage – Roadmap

Outer Jacket


Concept and Requirements

Accident Research & Power Train Concept

L-H2 Tank System:

Definition & Requirements

Package


Liquid Composite Moulding (LCM) Process (RTM, VARI)

Material & Technology Development

Dry reinforcement

Preform

Mold closure

Finishedpart

Vacuum

Resin injection

Vacuum foil

P1 ≤ Pat < P

Evt. Vacuum

Resin injection

Session 3.2 Cryogenic Storage Systems G. Bartlok 9Metallic Coating


Liner Concepts – Outer Jacket & Inner Tank

Moisture, air, oil, etc

Outgassing

Outer Jacket Composite

Hydrogen

Outgassing

Inner Tank Composite

High Vacuum: 10-5 – 10-6mBar

Hydrogen

Liner

Aluminium Sheet


Manufacturing of Cylindrical Outer Jacket

Manufacturing & pre-assembly

Proof of Feasibility

Flexible pipe


Critical Load Case: Buckling

Calculated Weight:

17,1 kg

Real Weight:

17,6 kg (17,1kg + 0,5 kg Resin Finish)


Outer Jacket – Validation of Calculation


Test of Cylindrical Outer Jacket

Basic tests

• Excessive pressure tests

• Vacuum tests

• Temperature cycling tests (- 196 °C up to + 85 °C)

• Imperfection tests




Metallic Coating for Inner Tank

Evaluation• Visual Inspection: Blisters, etc• Cross-Cut (before and after thermal shocks)• Flatwise Tensile Tests (Adhesion)

Tests• Thermal shock• Outgassing• Permeation• Pressure cycle tests

Evaluation• Micrographs (before and after• Permeation thermal shocks)


50 µmCFRP

CoatingLayersCFRP Vessel (200 dm³)

with Galvanic Coating

Metallic Coating for Inner Tank

• Metallic plating of large CFRP Structures Sample

• ensure Vacuum Stability




Fibre Preform Technology for Inner Tank

• Design & Layout of Composite Substructures

• Load optimised Wall Thickness / Fibre Orientation

• No Fibre Cut / Waste

CAD Model Fibre Preform Impregnated Dome



Assembly Sequence of Inner Tank

Assembly Jig



Bolt

Sensor calibration:

• Strain-gauges

• Temperature sensors

Cone

Assembly of Inner Tank

Dome


Computed Weight:

10 kg CFRP + 3 kg Metal Parts

Real Weight:

13,5 kg (with Sensors)


Inner Tank – Validation of Calculation



• Material Validation:Coupon & Component Test Plan

- more than 20 plates- 342 samples

Large test series at different temperatures: 25°C, 80°C and 120°C

Process: LCMFibres: T700 (M46 local reinforcement)Matrix: EPLiner form: SheetLiner material: Aluminium

Free-form Outer Jacket

• Set of MaterialRequirements

• Material & Process Pre-selection:

• Design Pre-Selection


Fre

e-F

orm

Cyl

indr

ical

Design Process of Cylindrical and Free-form Tank appyling the same Design Elements

Concept and Requirements

Free-form Inner Tank




• Set of Material Requirements

• Design Pre-selection

• Material & Process Pre-Selectionas a Result of:

• Literature research & material requirements• Analysis Results• Recycling aspects & assembly• Pre-selected design option• Evaluation criteria & trade-offs• Cryo-materials report

Materials: FRPProcess: LCMFibres: M46 / T700Matrix: Thermoset: EPLiner form: Galvanic coatingLiner material:Aluminium, Gold,

Copper, ..

FE Calculation

Weight (Inner Vessel):approx. 19 kg



• Material ValidationCoupon & Component TestsA large test series has been carried out- for different materials- at different temperatures: -253°C, 25°C, 80°C, 120°C

~60Coating tests8 plates

4Insert tests4 Tubes

~25Tension Tube tests2 plates / 1 tube

56Fibre VolumeAdhesive TestsCoefficient of thermal expansion

3 plates

408Ply- and Laminate Properties(ILS, Tensile, Compression, etc)

6 plates

# of TestsTests# CFRP components




• Material Validation (Cont.)

Compression Tests Adhesive Tests Tension Tube Tests

Insert Tests Filler 3D-Vacuum Bag



Outer Jackete.g. GFRP, CFRP

Thermal Insulation

Metallic Linere.g. Aluminum, Steel

Inner Tanke.g. CFRP

“Free-form”Tank Virtual Model

Session 1.2: IntroductoryLectures

K. Hall

Session 3.2: Cryogenic Storage Systems

Dr. G. Bartlok

25th – 29th September 2006Ingolstadt

16 Storhy Train-In Session 3 1 Cryoiii

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