TECHNOLOGY AND CODE article
Front. Appl. Math. Stat.
Sec. Numerical Analysis and Scientific Computation
Volume 11 - 2025 | doi: 10.3389/fams.2025.1625013
Computational Modeling and Experimental Investigation of Thread Fatigue in Ultra-High-Pressure Hydrogen Storage Vessels
Provisionally accepted
Xue Jiao
Yin Rui feng*- Hebei GEO University, Shijiazhuang, China
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This study presents a comprehensive computational and experimental investigation of thread fatigue behavior in ultra-high-pressure hydrogen storage vessels. A high-fidelity finite element model, incorporating axisymmetric assumptions and nonlinear material properties, is developed to simulate stress concentration and crack propagation under multiaxial cyclic loading. Crack growth is evaluated using an iterative fracture mechanics approach based on stress intensity factors, with polynomial fitting applied to characterize axial stress distributions. The influence of hydrogen embrittlement is explicitly considered in the fatigue life prediction through thresholdbased stress intensity criteria. To validate the computational results, fatigue experiments are conducted on SA-372 J steel vessels under controlled high-pressure hydrogen environments. The computational prediction indicated a fatigue life of approximately 613,190 cycles, while experimental results showed no measurable leakage or thread damage after 60,000 cycles, confirming excellent agreement and validating the model's accuracy. This work establishes a reliable computational framework for predicting the fatigue life of threaded connections, offering valuable design insights to improve the safety and durability of hydrogen storage vessels operating under extreme service conditions.
Keywords: Thread fatigue, hydrogen storage vessel, Finite Element Modeling, Crack p ropagation, computational mechanics, hydrogen embrittlement
Received: 08 May 2025; Accepted: 29 Jul 2025.
Copyright: © 2025 Jiao and feng. This is an open-access article distributed under the terms of the Creative Commons Attribution License (CC BY). The use, distribution or reproduction in other forums is permitted, provided the original author(s) or licensor are credited and that the original publication in this journal is cited, in accordance with accepted academic practice. No use, distribution or reproduction is permitted which does not comply with these terms.
* Correspondence: Yin Rui feng, Hebei GEO University, Shijiazhuang, China
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