Modular Additive Manufacturing for Next-generation Hydrogen Storage

紧凑型氢存储是氢动力汽车面临的主要挑战，目前最先进的存储容器太大，并且在危险的高压下运行。固态金属氢化物(MH)可以在更小的体积和更低的压力下存储大量的氢。然而，由于尚未开发出合适的船只，MH商店尚未投放市场。本项目将研究一种新型紧凑型MH储罐--S储罐的设计和制造。它将执行多种功能，包括热管理(由于放热和吸热的充放电循环)，以及MH床呼吸(由于MH在骑自行车时的膨胀和收缩)。为了满足这些要求，该项目将以一种全新的方式使用金属添加剂制造(AM)，使用单独的网格子部件或模块，这些部件或模块连接在一起创建容器内部。到项目结束时，学生将成功演示这种用于MH存储应用的新设计和制造方法。学生将结合AM工艺和计量、数值建模(例如有限元分析)和部件级测试(例如微结构分析、接头强度和泄漏测试)来研究这种模块化制造方法。他们将获得与现代设计和分析技术以及制造和材料科学相关的广泛技能和知识。

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.