Prediction analysis of depressurization-induced blistering damage in type IV hydrogen storage tank plastic liners

This study explores the influence of depressurization-induced cooling on blister formation in Type IV hydrogen storage cylinder liners by comparing two predictive models: one assuming isothermal conditions (Model 1) and another accounting for thermal effects (Model 2). Model 1 predicts more severe blistering than Model 2 under specific conditions—liner thicknesses of 1–4 mm with 10–30 h depressurization at 0 °C, and 5 mm with 30 h at 0 °C—while Model 2 indicates greater damage in alternative scenarios. Parametric analysis identifies key mitigation strategies: increasing the initial temperature, prolonging depressurization time, and reducing liner thickness, with thickness exhibiting the strongest impact. Sensitivity analysis ranks thickness as the most critical parameter, followed by depressurization rate and temperature. These findings underscore the necessity of thermo-mechanical coupling in accurately predicting blister damage and offer essential design guidelines to improve the structural reliability of hydrogen storage systems through integrated control of thermal and mechanical loading conditions.