Abstract
This study investigates the advanced fabrication of Type-I ultra-high pressure vessels via the hot-tube spinning process, unveiling previously undocumented deformation mechanisms critical to the creation of seamless vessels with significant wall thicknesses, exemplified by a 64 mm gauge. In compliance with the criteria of ASME SEC VIII Div. 1 and Div. 3, the research calculates the minimal wall thickness required for these vessels to endure a hydrogen pressure of 99 MPa. Finite element analysis is employed to analyze stress distributions, thus enhancing the understanding of the vessels’ structural integrity. Simulations executed with Forge NxT software reveal distinct material behaviors, including build-up phenomena and the non-uniform curvature of the dome section. These findings are validated by experimental trials, indicating a strong alignment with the theoretical models. The objective of the research is to integrate simulation and real-world production, facilitating comprehensive investigations into how manufacturing parameters influence vessel formation and the occurrence of defects. Discrepancies in wall thickness between simulated and actual test results are confined within a 10% margin of error, verifying the operational safety of the vessels at the critical pressure limit.
Similar content being viewed by others
References
Kreps BH (2020) The rising costs of fossil-fuel extraction: an energy crisis that will not go away. Am J Econ Sociol 79(3):695–717
Perera F (2018) Pollution from fossil-fuel combustion is the leading environmental threat to global pediatric health and equity: solutions exist. Int J Environ Res Public Health 15(1):16
Alazemi J, Andrews J (2015) Automotive hydrogen fuelling stations: an international review. Renew Sustain Energy Rev 48:483–499
Hardy B, Tamburello D, Corgnale C (2018) Hydrogen storage adsorbent systems acceptability envelope. Int J Hydrogen Energy 43(42):19528–19539
Grüger F, Dylewski L, Robinius M, Stolten D (2018) Carsharing with fuel cell vehicles: sizing hydrogen refueling stations based on refueling behavior. Appl Energy 228:1540–1549
Tsuda K, Kimura S, Takaki T, Toyofuku Y, Adaniya K, Shinto K, Miyoshi K, Hirata K, Christiani L, Takada M et al (2014) Design proposal for hydrogen refueling infrastructure deployment in the Northeastern United States. Elsevier
Kim H, Eom M, Kim B-I (2020) Development of strategic hydrogen refueling station deployment plan for Korea. Int J Hydrogen Energy 45(38):19900–19911
Zheng J, Liu X, Xu P, Liu P, Zhao Y, Yang J (2012) Development of high pressure gaseous hydrogen storage technologies. Int J Hydrogen Energy 37(1):1048–1057
Fuse M, Noguchi H, Seya H (2021) Near-term location planning of hydrogen refueling stations in Yokohama city. Int J Hydrogen Energy 46(23):12272–12279
Abdalla AM, Hossain S, Nisfindy OB, Azad AT, Dawood M, Azad AK (2018) Hydrogen production, storage, transportation and key challenges with applications: a review. Energy Convers Manage 165:602–627
Moradi R, Groth KM (2019) Hydrogen storage and delivery: review of the state of the art technologies and risk and reliability analysis. Int J Hydrogen Energy 44(23):12254–12269
Mayyas A, Mann M (2019) Manufacturing competitiveness analysis for hydrogen refueling stations. Int J Hydrogen Energy 44(18):9121–9142
Elgowainy A, Mintz M, Kelly B, Hooks M, Paster M (2008) Optimization of compression and storage requirements at hydrogen refueling stations. In: ASME Pressure vessels and piping conference, vol 48289, pp 131–136
Barthélémy H, Weber M, Barbier F (2017) Hydrogen storage: recent improvements and industrial perspectives. Int J Hydrogen Energy 42(11):7254–7262
Kim C, Park J, Kim C, Choi J (2004) Expert system for process planning of pressure vessel fabrication by deep drawing and ironing. J Mater Process Technol 155:1465–1473
Lee D-H, Park S-C, Kim B-M, Lee K-H (2018) Control method for forming roller in dome spinning process of 34CrMo4 alloy steel pipe at elevated temperature. Journal of the Korean Society of Marine Engineering 42(10):807–811
Quigley E, Monaghan J (2000) Metal forming: an analysis of spinning processes. J Mater Process Technol 103(1):114–119
Kong Q, Yu Z, Zhao Y, Wang H, Lin Z (2017) A study of severe flange wrinkling in first-pass conventional spinning of hemispherical part. Int J Ad Manuf Technol 93:3583–3598
Roy BK, Korkolis YP, Arai Y, Araki W, Iijima T, Kouyama J (2020) Experimental and numerical investigation of deformation characteristics during tube spinning. Int J Adv Manuf Technol 110:1851–1867
Zoghi H, Fallahi Arezoodar A, Sayeaftabi M (2012) Effect of feed and roller contact start point on strain and residual stress distribution in dome forming of steel tube by spinning at an elevated temperature. Proceedings of the institution of mechanical engineers, part b: journal of engineering manufacture 226(11):1880–1890
Zoghi H, Fallahi Arezoodar A (2013) Finite element study of stress and strain state during hot tube necking process. Proceedings of the institution of mechanical engineers, part b: journal of engineering manufacture 227(4):551–564
Zheng J, Li L, Chen R, Xu P, Kai F (2008) High pressure steel storage vessels used in hydrogen refueling station. J Press Vessel Technol 130(1)
Zhang F, Zhao P, Niu M, Maddy J (2016) The survey of key technologies in hydrogen energy storage. Int J Hydrogen Energy 41(33):14535–14552
Nibur KA, San Marchi C, Somerday BP (2010) Fracture and fatigue tolerant steel pressure vessels for gaseous hydrogen. In: Pressure vessels and piping conference, vol 49255, pp 949–958
Hua Z, Zhang X, Zheng J, Gu C-H, Cui T, Zhao Y, Peng W (2017) Hydrogen-enhanced fatigue life analysis of Cr-Mo steel high-pressure vessels. Int J Hydrogen Energy 42:12005–12014
Carr S, Zhang F, Liu F, Du Z, Maddy J (2016) Optimal operation of a hydrogen refuelling station combined with wind power in the electricity market. Int J Hydrogen Energy 41(46):21057–21066
Gökçek M, Kale C (2018) Optimal design of a hydrogen refuelling station (HRFS) powered by hybrid power system. Energy Convers Manage 161:215–224
Boiler A (2019) ASME boiler and pressure vessel code an international code Section VIII Division I. Am Soc Mech Eng New York, ???
Boiler A (2019) ASME boiler and pressure vessel code an international code Section VIII Division III. Am Soc Mech Eng New York ???
Chen X, Zhang B, Du Y, Liu M, Bai R, Si Y, Liu B, Jung D-W, Osaka A (2022) Constitutive model parameter identification based on optimization method and formability analysis for Ti6Al4V alloy. Materials 15(5). https://doi.org/10.3390/ma15051748
Acknowledgements
This work was supported by the Materials/Parts Technology Development Program (No.20015929) funded by the Ministry of Trade, Industry, and Energy (MI, Korea).
Author information
Authors and Affiliations
Contributions
Rivaldo Mersis Brilianto: investigation, formal analysis, data curation, validation, software, writing—original draft; Gunyoung Park: project administration, conceptualization, methodology, supervision, writing—review and editing; Young Bin Seo: software, investigation, data curation; Chul Kim: supervision, funding acquisition, writing—review and editing.
Corresponding author
Ethics declarations
Competing interests
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Brilianto, R.M., Park, G., Seo, Y.B. et al. Hot-tube spinning process for manufacturing ultra-high pressure vessels (Type-I): process planning and implementation. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13666-w
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s00170-024-13666-w