Composites in high-pressure hydrogen storage: A review of multiscale characterization and mechanical behavior

Abstract

Environmental protection and sustainable development remain key concerns for all stakeholders. In this context, hydrogen has emerged as a particularly promising energy vector for electricity and heat generation, contributing to the transition toward clean energy solutions. However, the refueling of high-pressure hydrogen tanks can lead to a rapid increase in the internal temperature of the storage cylinder, potentially causing a decrease in the state of charge, damage to tank walls, and, ultimately, safety concerns. This paper provides a detailed review of hydrogen storage technologies, with a particular focus on Type IV tanks for automotive applications. These tanks, characterized by a polymer liner fully wrapped in carbon fiber composites, are pivotal for achieving high-pressure containment while maintaining lightweight properties. To understand and address critical challenges, the study conducts an in-depth examination of the mechanical behavior and failure mechanisms of laminated composites across multiple scales. Through advanced multiscale characterization methods, including infrared thermography, X-ray tomography, acoustic emission, and digital image correlation, the research investigates how these materials respond under impact and cyclic loading conditions. Key failure mechanisms, such as matrix cracking, fiber breakage, and delamination, are explored to elucidate their progressive development and impact on the structural integrity of composites. The study also examines residual properties following dynamic loading to provide a comprehensive understanding of long-term performance under real-world conditions. Findings emphasize the importance of multiscale coupling from macro to microstructure to achieve accurate modeling and prediction of composite behavior. Insights from this research aim to optimize the design and durability of hydrogen storage systems, enabling safer and more efficient implementation in the automotive sector. This review concludes by summarizing the implications of these findings for enhancing the performance and safety of high-pressure hydrogen storage technologies.