Open Access

Entwicklung und Validierung eines Kryodruck-Tanksystems für Wasserstoff-Fahrzeuge. Darstellung der Versuchsergebnisse und des Normierungsvorschlags.

For fully carbon fibre wrapped pressure vessels with load sharing metallic liner (Type III), it was recognized that the state of residual stress given after the autofrettage process can change even if the vessel is stored without pressure. This change is influenced by temperature and time and has a direct effect on the residual lifetime of the vessel. To study the influence of the temperature on the state of residual stress an analytical model was applied which is based on the Classical Laminate Theory (CLT). According to the model, the critical conditions leading to a decrease in lifetime were identified. To confirm the results of the model temperature cycle tests were carried out. The results of the tests are compared with the analytical model and a finite element model. To investigate the influence of time on the state of residual stress, tests on vessels were performed. The tested vessels were aged without any pressure for a longer period of time after the autofrettage process. During these tests, the strain of the vessels was monitored.

Composite materials show a degradation of properties depending on Service life. This creates the necessity to find tailored methods to determine strength and residual strength of composite cylinders. The determination can be done e.g. by load cycles tests. The result needs a Statistical assessment for the precise description of strength. Especially the Statistical assessment of load cycle strength properties has a high uncertainty. It is unclear if a Log-Normal distribution, a WEIBULL distribution or others, describe the scatter behaviour of residual strength properties correctly. Distribution functions aim at approximating the frequency of occurrence of residual load cycle strength for high survival rates. An assumption has to be found and confirmed to prevent overestimation of reliability.

A silica-rich residue from waste-water treatment of chlorosilane production was tested for its applicability for the production of one-part geopolymers. The residue was blended with solid sodium aluminate, the blend activated with water and cured at 70 °C. The degree of reaction and strength were determined after 1,3, and 7 days. The reaction products were analyzed by means of powder X-ray diffraction (XRD), scanning electron microscopy (SEM), nitrogen Sorption, and small-angle X-ray Scattering (SAXS). Until the third day of curing the degree of reaction of the residue reached 51% and the strength reached 8.9 MPa. The reaction product was identified as geopolymer containing zeolite A. The results thus confirmed that the residue may be used in the production of geopolymers. However, from 3 to 7 days of curing no further progress of reaction was observed and the strength slightly decreased. It was observed that even harsh vacuum drying left some water, presumably zeolitic water and surface hydroxyl groups, in the hardened geopolymer, the volume fraction of the emptied pores was approximately 45%. The SEM and SAXS analyses showed the gel-like microstructure of the geopolymer with diameters of the gel particles of about 70 nm on average. In line with this colloidal particle size, the specific surface area of the geopolymer was measured by SAXS to be approximately 120 m2/g. On the contrary, nitrogen Sorption measurements yielded a specific surface area of only 13 mz/g and did not show the presence of micropores, which is attributable to the inaccessibility of the pores of the geopolymer and the zeolites for nitrogen at the measurement temperature.

Mixing and curing of geopolymers and related alkali-activated materials without storage and handling of highly alkaline solutions possesses advantages regarding safety and economic viability. One possible approach is to produce these materials from solid silica feedstocks and solid sodium aluminate, and subsequent mixing with water. We present a comparison between geopolymers and aluminosilicate gel-zeolite composites synthesized by this route from different silica feedstocks (by-product silica from chlorosilane production, microsilica, rice husk ash) and with different SiO2/Al2O3 ratios, using results from XRD, NMR, SEM, thermal analysis, mechanical and acid resistance testing. The use of rice husk ash favors formation of a fully amorphous geopolymer with high strength. Utilization of the other silica feedstocks leads to formation of aluminosilicate gel-zeolite composites, the amount and kind of zeolites depending on the feedstock and the SiO2/Al2O3 ratio. These composites show beneficial dehydration behavior, viz. no distinct dehydration step of thermal strain, with the phase assemblage after heating to 1000°C controlled by the starting composition. Mortars produced from both, the geopolymers as well as the composites, exhibit high resistance to sulfuric acid attack, making them promising materials for the construction and the repair of industrial and sewer structures.