• Journal of Korea Foundry Society
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• v.28 no.1
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• pp.25-30
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• 2008

To develop a functionally graded microstructure of cylindrical liner, effect of centrifugal casting parameters such as pouring temperature of hyper-eutectic Al-Si alloy melt, mold pre-heating temperature, and rotational frequency of mold on distribution of primary Si particles across wall thickness were investigated. Segregation tendency of Si particles toward inner side of cylindrical liner increased as the increase of rotational frequency of mold, pouring temperature of melt and mold pre-heating temperature. Especially, distribution density of primary Si particles within 1.5 mm from inner surface of cylindrical liner was above 35% under the centrifugal casting condition of $750^{\circ}C$ melt pouring temperature, $300^{\circ}C$ mold pre-heating temperature, and 2500 rpm mold rotational frequency.

• Journal of the Korean Institute of Gas
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• v.15 no.4
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• pp.21-26
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• 2011

Type-3 cylinder liner has a limitation of machining the standard specimen for fracture toughness test because it has approximately 5 mm in thickness as well as a curvature. Hence, it needs to be employed a miniature specimen test technique to evaluate fracture toughness of the cylinder liner. In this study, small punch (SP) test method was employed to evaluate fracture toughness of the cylinder liner. Load-displacement curve result measured from the SP test showed that the liner material was failed during membrane stretching in the general SP load-displacement curve. Additionally, it was shown that liner material was isotropic although the amount of plastic deformation was different depending on the direction due to manufacturing process characteristics. Fracture toughness, $J_{Ic}$, was evaluated using the SP test data. The value of fracture toughness obtained was $13.0kJ/m^2$. This value was similar to that of the same kind of materials. Therefore, the fracture toughness evaluated using the SP test data was reasonable.

• Journal of Mechanical Science and Technology
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• v.17 no.2
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• pp.171-180
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• 2003

One of the most significant problems in the processing of composite materials is residual stress. The high residual stress may cause cracking in the matrix without external loads and degrade the integrity of composite structures. In this study, thermo-viscoelastic residual stresses occurred in an aluminum liner-inserted polymer composite cylinder are investigated. This type of the structure is used for rocket fuselage due to the convenience to attach payloads and equipment to the metal liner by machining. The time and degree of cure dependent thermo-viscoelastic constitutive equations are developed and coupled with a thermo-chemical process model. These equations are solved with the finite element method to predict the residual stresses in the composite cylinder and also in the interface between the liner and the composite during cure.

• Journal of the Korean Institute of Gas
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• v.15 no.1
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• pp.35-39
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• 2011

The purpose of this paper is to analyze affecting ratios of strength safety in carbon fiber layer thickness of a composite fuel tank for FEV vehicles. To investigate affecting ratios by FEM modeling, the equivalent von Mises stress has been computed on the aluminum liner and carbon fiber layers of composite fuel tanks in hoop and helical directions respectively. According to the FEM results, the affecting ratios of an aluminum liner on the equivalent stress are 77.5% in hoop direction, 18.11% in $70^{\circ}C$ winded helical direction and 4.39% in $12^{\circ}C$ winded helical direction. These trends on the strength safety of carbon fiber layers have been shown as those of an aluminum liner even though the layer thickness ratio of $12^{\circ}C$ inclined carbon fiber is very high of 42% compared with that of hoop layer thickness. Thus, the computed results show that the strength safety of a carbon fiber fuel tank is more influenced by the winding angle rather than the fiber thickness of carbon fiber layers.

• 한국신재생에너지학회:학술대회논문집
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• 2007.11a
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• pp.165-168
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• 2007

The objective of this study is to demonstrate and commercialized for on-board fuel storage system for the hydrogen fuel cell vehicles. Type3 composite cylinder is consisting of the full wrapped composites on a seamless aluminum liner. Especially, the seamless aluminum liner has been commercialized with development of fabrication through this study. The key technologies, including design, analysis and the optimized filament winding process for 350bar composite cylinder, were established and verified with design qualification test in accordance with international standard. And the facilities for fabrication and design qualification test have been constructed.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.275-280
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• 2008

To improve the durability of a hydrogen pressure vessel which is applied high-pressure, it needs the autofrettage process which induces compressive residual stress in the Aluminum liner. This study presents the elasto-plastic analysis to predict the behavior of structure accurately, and the Tsai-Wu failure criterion is applied to predict failure of pressure vessel of Aluminum liner and composite materials. Generally, plastic analysis is more complex than elastic analysis and has much time to predict. To complement its weakness, the AxicomPro(EXCEL program), applied radial return algorithm and nonlinear classical laminate theory (CLT), is developed for predicting results with more simple and accurate than the existing finite element analysis programs.

• Journal of the Korean Institute of Gas
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• v.15 no.6
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• pp.57-62
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• 2011

In this study, the optimized design for 130 liter storage fuel tank with 70MPa filling pressure has been investigated using a FEM technique and Taguchi design method. The strength safety of a composite fuel tank in which is fabricated by an aluminum liner of 6061-T6 material and carbon fiber wound composite layers of T800-24K has been analyzed based on the criterion of design safety of US DOT-CFFC and Korean Standard. The FEM computed results on the stress safety of 70MPa hydrogen gas tank were compared with a criterion of a stress ratio, 2.4 of US DOT-CFFC and Korean Standard, and indicated the safety. Thus, the optimized design elements based on the Taguchi's method were recommended as an aluminum liner thickness of 6.4mm, a carbon fiber laminate thickness in hoop direction of 31mm and a carbon fiber laminate thickness in helical direction of 10.2mm, which is represented by a design model of No. 5.

• Journal of the Korean Institute of Gas
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• v.15 no.5
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• pp.37-41
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• 2011

This paper presents the strength safety of a hydrogen gas composite fuel tank, which is analyzed using a FEM based on the criterion of US DOT-CFFC and Korean Standard. A hydrogen gas composite tank in which is fabricated by an aluminum liner of 6061-T6 material and carbon fiber wound composite layers of T800-24K is charged with a filling pressure of 70MPa and a gas storage capacity of 130 liter. The FEM results indicated that von Mises stress, 255.2MPa of an aluminum liner inner tank is low compared with that of 95% yield strength, 272MPa. And a carbon fiber stress ratio of a composite fuel tank is 3.11 in hoop direction and 3.04 in helical direction. These data indicate that a carbon fiber gas tank is safe in comparison to that of a recommended criterion of 2.4 stress ratio. Thus, the proposed composite tank with 130 liter capacity and 70MPa filling pressure is usable in strength safety.

• Journal of the Korean Society of Propulsion Engineers
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• v.11 no.2
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• pp.26-36
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• 2007

The thermal response characteristics of nozzle liner for a solid rocket motor applying highly aluminized PCP or HTPB propellant with slotted tube grain have been investigated. The SEM photographs of aluminum oxide particles taken from nozzle liner show that the PCP propellant with the finer and less contents of oxidizer can offer greater possibility for increasing aluminum agglomeration than the HTPB propellant. The PCP propellant shows locally greater mechanical erosion at 4 circumferential areas of the nozzle entrance in line with grain slot due to the impingement of large particles, but the HTPB propellant shows greater thermochemical ablation at the nozzle blast tube, the throat insert and the exit cone because of relatively much more mole fraction of $H_2O\;and\;CO_2$ in combustion gases.

• Journal of the Korean Institute of Gas
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• v.16 no.2
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• pp.25-30
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• 2012

This paper presents a stress safety of a composite pressure cylinder in which is composed of an aluminum liner and composite layers with carbon fiber/epoxy and glass fiber/epoxy resigns. The composite pressure cylinder for a hydrogen gas vehicle contains 9.2 liter hydrogen gas, and hydrogen gases are compressed by a filling pressure of 35MPa. The FEM computed results are analyzed based on the US DOT-CFFC basic requirement for a hydrogen gas cylinder and KS B ISO specification. The FEM results indicate that the stress, 247MPa of an aluminum liner is sufficiently low compared with that of 272MPa, which is 95% level of a yield stress for aluminum. And, the carbon fiber composite layers in which are wound on the surface of an aluminum cylinder are safe because the maximum carbon fiber stresses from 29.43% to 28.87% in hoop and helical directions are below 30% for a given minimum required burst pressure level, respectively. The carbon fiber composite layers are also safe because the stress ratios from 3.40 to 3.46 in hoop and helical directions are above 2.4 for a minimum safety level, respectively.