Modular Additive Manufacturing for Next-generation Hydrogen Storage

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Compact hydrogen storage is a major challenge for hydrogen powered vehicles, with current state-of-the-art storage vessels being too large and operating at dangerously high pressures. Solid state metal hydrides (MH) can store large quantities of hydrogen in much smaller volumes and at lower pressure. However, MH stores have not made it to market because suitable vessels have not yet been developed. This project will investigate the design and manufacture of a new type of compact MH storage vessel - the Type S vessel. It will perform multiple functions, including heat management (due to exothermic and endothermic charging and discharging cycles), and MH bed breathing (due to MH expansion and contraction whilst cycling). To address these requirements, the project will use metal additive manufacturing (AM) in an entirely new way, using individual latticed sub-components, or modules, which are joined together to create the vessel interior. By the end of the project, the student will have successfully demonstrated this new design and manufacturing approach for MH storage applications. The student will investigate this modular manufacturing approach with a combination of AM processing and metrology, numerical modelling (e.g., finite element analysis), and component-level testing (e.g., microstructure analysis, joint strength and leak testing). They will gain a broad set of skills and knowledge relevant to modern design and analysis techniques, as well as manufacturing and materials science.