What material is liquid hydrogen fuel tank?
Liquid hydrogen fuel tanks are typically built from lightweight, cryogenic-friendly materials. In space launch vehicles, aluminum alloys are standard; in consumer hydrogen vehicles, an aluminum inner liner with a carbon-fiber composite overwrap is common, all surrounded by superb insulation to minimize boil-off.
This article examines the materials used in liquid hydrogen tanks across different applications, explaining why certain metals and composites are chosen, and how insulation and safety considerations influence design.
Rockets and space launch vehicles
Rockets store liquid hydrogen at cryogenic temperatures (around −253°C or 20 K). The materials must maintain strength and integrity at these temperatures while keeping weight low. The following materials and design choices are typical in LH2 tanks for space vehicles.
Cryogenic-compatible metals and components
- Aluminum alloys for tank shells and major structural components (common examples include aluminum alloys in the 2000–7000 series; higher-strength aluminum–lithium alloys such as 2195 are used to improve strength-to-weight).
- Stainless steel or nickel-based alloys for internal liners, manifolds, and components that require excellent cryogenic toughness or chemical compatibility with liquid hydrogen.
- Insulation materials and methods, such as vacuum-insulated shells with foam or perlite, to reduce boil-off by minimizing heat transfer into the tank.
In practice, the combination of aluminum-based shells with cryogenic insulation has proven reliable and easy to manufacture at scale, while ongoing material research continues to push the envelope on stiffness, weight, and boil-off reduction.
Hydrogen fuel tanks in passenger vehicles
Most modern hydrogen fuel-cell vehicles use Type IV tanks, which prioritize lightweight construction, robust safety margins, and excellent thermal performance. These tanks typically feature a thin metal liner with a high-strength composite overwrap and vacuum insulation to minimize hydrogen loss.
Composite overwrapped and liner materials
- Inner liner: a thin aluminum alloy liner (commonly in the 6000-series or similar lightweight aluminum alloys) that provides a durable, corrosion-resistant surface in contact with liquid hydrogen.
- Outer wrap: carbon fiber reinforced polymer (CFRP) overwrap, providing high strength-to-weight ratio and allowing a compact, rugged exterior.
- Insulation: vacuum insulation, often combined with multi-layer insulation or aerogel-based materials to reduce heat ingress and limit boil-off.
These design choices enable hydrogen tanks in cars to be lightweight enough for practical vehicle use while maintaining safety under a range of operating conditions. Some newer designs continue to optimize liner thickness, fiber layup, and insulation to further reduce boil-off and cost.
Summary
Liquid hydrogen tanks rely on materials that perform at cryogenic temperatures and minimize weight. In rockets, aluminum alloys (including aluminum–lithium variants) form the primary tank structure, paired with insulation to control heat transfer. In passenger vehicles, the standard is an aluminum alloy inner liner with a CFRP overwrap and vacuum insulation, balancing safety, weight, and efficiency. Across both applications, the choice of material is driven by cryogenic compatibility, mechanical strength, manufacturability, and cost.
What are the materials used in liquid hydrogen fuel tanks?
Typically, the inner vessel material used is 304 SS and the outer vessel is a combination of 304 SS and carbon steel depending on location.
How much does a liquid hydrogen storage tank cost?
40,000 L Hydrogen Storage Tank at ₹ 1000000/piece | Mobile Storage Tanks in Pune | ID: 4489114633.
What happens if you puncture a hydrogen tank?
The Nature of Hydrogen: A Flammable and Volatile Gas
When stored under high pressure in tanks, even a minor leak can result in a dangerous explosion if the gas comes into contact with an ignition source.
