Topology optimization of gyroid structure-based metal hydride reactor for high-performance hydrogen storage

Numerous engineering applications stand to gain substantial advantages by mitigating structural weight. While methods for optimizing continuous solids and discrete frame structures have long been available, the advent of additive manufacturing techniques has ushered in the potential for intricate geometries. In contrast, the hydrogen fuel sector confronts a pivotal challenge: the need to develop efficient hydrogen storage systems. Solidstate compounds like metal hydrides (MH) present a compelling solution among various hydrogen storage technologies thanks to their inherent safety attributes and superior hydrogen volumetric density. Nonetheless, the limitation of MH lies in its gravimetric density, impeding its application in mobility contexts. A transformative strategy addresses this limitation by seamlessly integrating the reactor tank into the vehicle ' s frame and chassis. This study introduces a pioneering concept - an optimally designed MH container incorporating a gyroid structure. Subsequently, this innovative design underwent rigorous analysis, employing finite element analysis (FEA) and computational fluid dynamics, assessing mechanical properties, heat transfer capabilities, and the efficiency of hydrogen charging into the MH within the structure. Using topology optimization of solid isotropic material with penalization method, a 17 % increase in the chamber volume and a concurrent reduction of the material by nearly 50 %. This profound transformation positively impacted the reactor ' s volumetric and gravimetric density. Despite a measurable reduction in strength, the optimized structure demonstrated resilience, successfully withstanding prescribed mechanical shear loads. Furthermore, the structure exhibited impressive rigidity, with displacement below 0.2 mm, rendering it suitable and highly competent for integration into assembly components like vehicle frames or chassis. Notably, the optimized structure exhibited a promising enhancement in hydrogen charging rate.