Composite cylinders with metal liner are used for the storage of compressed hydrogen in automotive application. These hybrid pressure cylinders are designed for a nominal working pressure of up to 70 MPa. They also have to withstand a temperature range between -40 deg.C and +85 deg.C according GRPE draft and for short periods up to a maximum temperature of 140 deg. C during filling (fast filling). In order to exploit the material properties efficiently with a high degree of lightweight optimization and a high level of safety on the same time a better understanding of the structural behavior of hybrid designs is necessary. Work on this topic has been carried out in the frame of a work package on safety aspects and regulation (Subproject SAR) of the European IP StorHy. The temperature influence on the composite layers is distinctive due to there typical polymer material behavior. The stiffness of the composite layer is a function of temperature which influences global strains and stress levels (residual stresses) in operation. In order to do an accurate fatigue assessment of composite hybrid cylinders a realistic modeling of a representative temperature load is needed. For this, climate data has been evaluated which were collected in Europe over a period of 30 years. Assuming that the temperature follows a Gaussian (normal) distribution within the assessed period of 30 years, it is possible to generate a frequency distribution for different temperature classes for the cold extreme and the hot extreme. Combining these distributions leads to the overall temperature range distribution (frequency over temperature classes). The climatic temperature influence, the filling temperature and the pressure load have to be considered in combination with the operation profile of the storage cylinder to derive a complete load vector for an accurate assessment of the lifetime and safety level.
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