GB/T 35544-2025 (GB/T 35544-2017) PDF English
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Fully-wrapped carbon-fiber reinforced cylinders with an aluminum liner for the on-board storage of compressed hydrogen as a fuel for land vehicles
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GB/T 35544-2017: Fully wrapped carbon fiber reinforced cylinders with an aluminum liner for the on-board storage of compressed hydrogen as a fuel for land vehicles
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GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 23.020.30
J 74
Fully-wrapped carbon fiber reinforced cylinders with an
aluminum liner for the on-board storage of compressed
hydrogen as a fuel for land vehicles
[Including 2020XG1 No.1 Amendment List]
Issued on. DECEMBER 29, 2017
Implemented on. JULY 01, 2018
Issued by. General Administration of Quality Supervision, Inspection and
Quarantine of PRC;
Standardization Administration of PRC.
Table of Contents
Foreword... 3
1 Scope... 4
2 Normative references... 4
3 Terms, definitions, symbols... 6
4 Types, parameters, classifications, models... 9
5 Technical requirements... 10
6 Test methods and qualification indicators... 16
7 Inspection rules... 36
8 Marking, packaging, transport, storage... 40
9 Product certificate and batch inspection quality certificate... 41
Appendix A (Informative) Determination method of maximum allowable defect size of
aluminum liner... 44
Appendix B (Normative) Type test method and qualification index of temperature-
driven safety pressure relief device and valve... 46
References... 62
No.1 Amendment sheet... 63
1 Scope
This standard specifies the type and parameters, technical requirements, test methods,
inspection rules, marking, packaging, transportation, storage requirements of fully-
wrapped carbon fiber reinforced cylinders with an aluminum liner for the on-board
storage of compressed hydrogen as a fuel for land vehicles (hereinafter referred to as
gas cylinders).
This standard is applicable to the design and manufacture of refillable gas cylinders,
which have a nominal working pressure not exceeding 70 MPa, a nominal water volume
not exceeding 450 L, storage medium of compressed hydrogen, working temperature
not lower than -40 °C and not higher than 85 °C, fixed on road vehicles as fuel tanks.
Note. Gas cylinders for hydrogen supply, such as hydrogen fuel cell for urban rail transit, can
be manufactured and inspected with reference to this standard.
2 Normative references
The following documents are essential to the application of this document. For the dated
documents, only the versions with the dates indicated are applicable to this document;
for the undated documents, only the latest version (including all the amendments) is
applicable to this standard.
GB/T 192 General purpose metric screw threads - Basic profile
GB/T 196 General purpose metric screw threads - Basic dimensions
GB/T 197 General purpose metric screw threads - Tolerances
GB/T 228.1 Metallic materials - Tensile testing - Part 1.Method of test at room
temperature
GB/T 230.1 Metallic materials - Rockwell hardness test - Part 1.Test method
(scales A, B, C, D, E, F, G, H, K, N, T)
GB/T 231.1 Metallic materials - Brinell hardness test - Part 1.Test method
GB/T 232 Metallic materials - Bend test
3 Terms, definitions, symbols
3.1 Terms and definitions
The terms and definitions as defined in GB/T 13005, as well as the following terms and
definitions, apply to this document.
3.1.1
Aluminum liner
A seamless aluminum alloy container, whose outer surface is wrapped with carbon
fiber reinforced layer, to seal the gas and can or cannot withstand part of the pressure
load.
3.1.2
Fully-wrapped
A continuous wrapping method, which is carried out spirally and circumferentially
by carbon fiber, which is impregnated with the resin matrix, on the aluminum inner,
so that the circumferential and axial directions of the gas cylinder are enhanced.
3.1.3
Fully-wrapped cylinder
A gas cylinder, which is fully wound with a carbon fiber reinforced layer, on the
outer surface of the aluminum liner AND cured by heating.
3.1.4
Nominal working pressure
The limited filling pressure of the cylinder, at the reference temperature (15 °C).
3.2 Symbols
The following symbols apply to this document.
4 Types, parameters, classifications, models
4.1 Types
The body structure of the gas cylinder shall conform to the type shown in Figure 1, in
which the T-type is a convex bottom structure, whilst the S-type is a closed-end
structure.
4.2 Parameters
4.2.1 The nominal working pressure of the gas cylinder shall generally be 25 MPa, 35
MPa, 50 MPa or 70 MPa.
4.3 Category
Gas cylinders are divided into category A cylinders and category B cylinders. Category
A gas cylinders are gas cylinders, which have a nominal working pressure less than or
equal to 35 MPa; category B gas cylinders are gas cylinders, which have a nominal
working pressure greater than 35 MPa.
4.4 Models
The model designation of gas cylinder shall consist of the following parts.
Example. The category A fully-wrapped carbon fiber reinforced cylinders with an aluminium
liner for the on-board storage of compressed hydrogen as a fuel for land vehicles, whose
aluminum liner has a nominal outer diameter of 356 mm, a nominal water volume of 120 L, a
nominal working pressure of 35 MPa, an S-type structure, can be designated as. CHG3-356-
120-35 S/A.
5 Technical requirements
5.1 General requirements
5.1.1 Nominal water volume
The nominal water volume of category A gas cylinders is not more than 450 L; the
nominal water volume of category B gas cylinders is not more than 230 L.
5.1.3 Service life
The service life of category A gas cylinders is 15 years; the service life of category B
gas cylinders is 10 years. When the actual service life of the gas cylinder has not reached
the service life, BUT the number of fillings reaches the design cycle number, the gas
cylinder shall be scrapped.
5.1.5 Temperature range
During filling and use, the temperature of the gas cylinder shall not be lower than -
40 °C and not higher than 85 °C.
5.1.6 Hydrogen quality
The compressed hydrogen composition of the refillable gas cylinder shall meet the
quality requirements of hydrogen, which is used in fuel cell vehicles.
5.2 Materials
5.2.1 General requirements
The materials for manufacturing gas cylinders shall have the original quality certificate,
which is provided by the material manufacturer, OR a photocopy of the quality
certificate, which is stamped with the official seal of the material management
organization and signed (sealed) by the person in charge.
5.2.2 Aluminum liner
5.2.3 Resins
5.2.3.1 The impregnating material shall be a thermosetting resin, which has high heat
resistance and good stability, such as epoxy resin or modified epoxy resin. The
determination of epoxy equivalent of resin shall be carried out, in accordance with the
provisions of GB/T 4612.The glass transition temperature of resin materials shall be
determined, in accordance with the provisions of GB/T 19466.2; its value shall not be
lower than 105 °C.
5.3 Design
5.3.1 Aluminum liner
5.3.1.1 The end of the aluminum liner shall adopt a convex structure.
5.3.1.2 The end of the aluminum liner shall be designed with a gradient thickness; the
cylinder body and the end shall have a smooth transition.
5.3.2 Gas cylinders
5.3.2.1 The hydraulic test pressure of the gas cylinder shall not be lower than 1.5 times
the nominal working pressure.
5.3.2.2 The fiber stress ratio shall not be less than 2.25.
5.3.2.3 The minimum burst pressure of the gas cylinder shall not be lower than 2.25
times the nominal working pressure.
5.3.4 Maximum allowable defect size
Use the normal temperature pressure cycle test method of the cylinder with cracks OR
the engineering evaluation method based on fracture mechanics, to determine the
maximum allowable defect size, during the nondestructive testing of the aluminum liner,
as shown in Appendix A.
5.4 Manufacturing
5.4.1 General requirements
5.4.4 Fiber winding
5.4.4.1 Before winding the carbon fiber, the inner and outer surfaces of the aluminum
liner shall be cleaned; there shall be no debris, such as metal chips; measures shall be
taken to prevent galvanic corrosion between the outer surface of the aluminum liner
and the carbon fiber wrapping layer.
5.5 Accessories
6 Test methods and qualification indicators
6.1 Aluminum liner
6.1.1 Wall thickness and manufacturing tolerances
6.1.1.1 Test method
The wall thickness shall be measured, by an ultrasonic thickness gauge. The
manufacturing tolerance shall be checked, by standard or special measuring tools and
templates.
6.1.2 Internal and external surfaces
6.1.2.1 Test method
Visually inspect the outer surface. Use an endoscope, to inspect the inner surface.
6.1.2.2 Qualification index
The inner and outer surfaces of the aluminum liner shall meet the following
requirements.
6.1.3 Cylinder mouth thread
6.1.3.1 Test method
Visual inspection. Check with a gauge, which meets the GB/T 3934 standard or the
corresponding standard.
6.1.3.2 Qualification index
The thread of the cylinder mouth shall meet the following requirements.
6.1.4 Performance measurement of aluminum liner after heat treatment
6.1.4.1 Sampling
The sampling requirements are as follows.
6.1.4.2 Tensile test
6.1.4.2.1 Test method
The tensile test shall meet the following requirements.
6.1.4.2.2 Qualification index
The measured tensile strength Rm and the 0.2% non-proportional elongation strength
Rp0.2 shall meet the guaranteed value of the design and manufacturing organization; the
elongation at break A shall not be less than 12%.
6.1.4.3 Metallographic test
6.1.4.4 Cold bending test
6.1.4.4.1 Test method
The cold bending test shall be carried out, according to the method specified in GB/T
232.Meanwhile it shall meet the following requirements.
6.1.4.4.2 Qualification index
Use visual inspection. The specimen shall not have crack.
6.1.4.5 Flattening test
6.1.4.5.1 Test method
The specimen preparation and test methods are performed, according to GB/T 11640.
The specimen shall be flattened to the distance H, which is specified in Table 3.
6.2 Gas cylinders
6.2.1 Mechanical properties of wrapping layer
6.2.1.1 Interlaminar shear test
6.2.2 Appearance of the wrapping layer
6.2.2.1 Test method
Visual inspection.
6.2.2.2 Qualification index
There shall be no defects, such as bare fibers, fiber breakage, resin buildup,
delamination, fiber non-saturation.
6.2.3 Hydrostatic test
7 Inspection rules
7.1 Exit-factory inspection
7.1.1 Inspection one by one
The aluminum liner and gas cylinder shall be inspected one by one, according to the
items specified in Table 6.
7.1.2 Batch inspection
7.1.2.1 Inspection items
Both the aluminum liner and the gas cylinder shall be subject to batch inspection,
according to the items specified in Table 6.
7.1.2.2 Sampling rules
7.1.2.2.2 Gas cylinders
Two cylinders are randomly selected from each batch of gas cylinders, one is subjected
to the water pressure burst test, whilst the other is subjected to the normal temperature
pressure cycle test.
7.2 Type test
7.2.1 Newly designed gas cylinders shall be type tested, according to the items specified
in Table 6.
7.2.2 The number of the same batch of gas cylinders, which are used for the type test,
shall not be less than 30.The number of liners, which are randomly selected for the type
test, shall be 1.The number of gas cylinders shall be as follows.
7.2.3 All liners and gas cylinders, which are subjected to the type test, shall be de-
functioned, after the test.
7.3 Design changes
7.3.1 Design changes are allowed, to reduce type test items. For design changes, in
addition to the one-by-one inspection and batch inspection, according to the items
specified in Table 6, the type test shall also be carried out again, according to the items
specified in Table 7.
7.3.4 Carbon fiber is manufactured from the same original material (initial material),
meanwhile the nominal fiber modulus and nominal fiber strength specified by the fiber
manufacturer do not exceed ±5% specified by the design prototype, THEN, it shall be
regarded as an equivalent fiber material.
7.3.5 Different types of resin materials shall be considered as new resin materials. such
as epoxy resin, modified epoxy resin, etc.
7.3.6 The same type and same kind of resin, which has equivalent chemical properties,
are equivalent resin materials.
8 Marking, packaging, transport, storage
8.1 Marking
8.1.1 A complete and clear manufacturing label and certified electronic label shall be
implanted on the surface layer OR under the protective layer of each gas cylinder's
wrapping layer, to form a permanent mark.
8.1.2 The character height of the gas cylinder's manufacturing label shall not be less
than 8 mm; the marking items shall at least include.
8.2 Packaging
8.2.1 According to the needs of the user, if it is exit-factory without cylinder valve,
THEN, the cylinder mouth shall be sealed by reliable measures, to prevent
contamination.
8.2.2 Gas cylinders shall be properly packaged, to prevent damage during transportation.
8.3 Transport
8.3.1 The transportation of gas cylinders shall comply with the relevant provisions of
the transportation department.
8.4 Storage
Gas cylinders shall be sorted and stored neatly. Store it in a dry, ventilated, cool place;
avoid sun exposure, high temperature, humidity; it is strictly prohibited from exposure
to strong acid, strong alkali, strong radiation; it is strictly prohibited from cutting,
scribing, throwing, violent impact.
9 Product certificate and batch inspection quality certificate
9.1 Product certificate
9.1.1 Each gas cylinder, which leaves the factory, shall be accompanied by a product
certificate. A product instruction manual shall be provided to the user.
9.1.2 The exit-factory product certificate shall at least contain the following contents.
9.1.3 The product instruction manual shall contain at least the following contents.
9.2 Batch inspection quality certificate
9.2.1 The contents of the batch inspection quality certificate shall include the batch
inspection items, which are specified in this standard.
9.2.2 Each batch of gas cylinders leaving the factory shall be accompanied by a batch
inspection quality certificate and a supervisory inspection certificate.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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