3D printed hydrogen storage systems using non-pyrophoric hydrogen storage alloys
A hydrogen storage system includes a hydrogen storage alloy containment vessel comprising an external pressure containment vessel and a thermally conductive compartmentalization network disposed within the pressure containment vessel. The compartmentalization network creates compartments within the pressure vessel within which a hydrogen storage alloy is disposed. One or both of the compartmentalization network and the pressure vessel may be formed by a 3D printing process, such as by Selective Laser Melting (SLM) and/or Direct Metal Laser Sintering (DMLS). The hydrogen storage alloy is a non-pyrophoric AB 2 Laves phase hydrogen storage alloy having: an A-site to B-site elemental ratio of not more than 0.5; and an alloy composition including (in at %): Zr: 2.0-5.5, Ti: 27-31.3, V: 8.3-9.9, Cr: 20.6-30.5, Mn: 25.4-33.0, Fe: 1.0-5.9, Al: 0.1-0.4, and/or Ni: 0.0-4.0.
1 . A hydrogen storage system comprising:
a hydrogen storage alloy containment vessel, wherein said hydrogen storage alloy containment vessel comprises:
an external pressure containment vessel;
a thermally conductive compartmentalization network disposed within said external pressure containment vessel, said thermally conductive compartmentalization network creating compartments within said pressure vessel within which a hydrogen storage alloy is disposed;
said hydrogen storage alloy disposed within said hydrogen storage alloy containment vessel, wherein said hydrogen storage alloy comprises a non-pyrophoric AB 2 Laves phase hydrogen storage alloy comprising:
an alloy composition including about (in at %): Zr: 2.0-5.5, Ti: 27-31.3, V: 8.3-9.9, Cr: 20.6-30.5, Mn: 25.4-33.0, Fe: 1.0-5.9, and Al: 0.1-0.4.
2 . The hydrogen storage system of claim 1 , wherein the hydrogen storage alloy further comprises an A-site to B-site elemental ratio of not more than about 0.5.
3 . The hydrogen storage system of claim 1 , wherein said alloy composition includes (in at %): Zr: 2.9-5.5, Ti: 27-30.3, V: 8.3-9.3, Cr: 20.6-26.5, Mn: 29.4-32.1, Fe: 1.5-5.9, and Al: 0.1-0.4.
4 . The hydrogen storage system of claim 1 , wherein said alloy composition further includes up to about 4 at % nickel as an equal substitute for up to about 2 at % chromium or up to about 2 at % manganese or both.
5 . The hydrogen storage system of claim 1 , wherein said alloy has a total hydrogen storage capacity of at least about 1.7 wt % at about 500 psi and about 20° C.
6 . The hydrogen storage system of claim 1 , wherein said alloy has a total hydrogen storage capacity of at least about 1.8 wt % at about 500 psi and about 20° C.
7 . The hydrogen storage system of claim 1 , wherein said alloy has a trapped hydrogen capacity of no more than about 0.25 wt % at about 14.5 psi and about 20° C.
8 . The hydrogen storage system of claim 1 , wherein said alloy has a trapped hydrogen capacity of no more than about 0.20 wt % at about 14.5 psi and about 20° C.
9 . The hydrogen storage system of claim 1 , wherein said alloy has a trapped hydrogen capacity of no more than about 0.15 wt % at about 14.5 psi and about 20° C.
10 . The hydrogen storage system of claim 1 , wherein said alloy has a trapped hydrogen capacity of no more than about 0.10 wt % at about 14.5 psi and about 20° C.
11 . The hydrogen storage system of claim 1 , wherein said alloy has a pressure composition temperature (PCT) isotherm slope of no more than about 0.8.
12 . The hydrogen storage system of claim 1 , wherein said alloy has a PCT isotherm slope of no more than about 0.7.
13 . The hydrogen storage system of claim 1 , wherein said alloy has a PCT isotherm slope of no more than about 0.6.
14 . The hydrogen storage system of claim 1 , wherein said alloy has a hysteresis of not more than about 0.5.
15 . The hydrogen storage system of claim 1 , wherein said alloy has a hysteresis of not more than about 0.4.
16 . The hydrogen storage system of claim 1 , wherein said alloy has a hysteresis of not more than about 0.3.
17 . The hydrogen storage system of claim 1 , wherein said alloy has a hysteresis of not more than about 0.2.
18 . The hydrogen storage system of claim 1 , wherein said alloy has a hysteresis of not more than about 0.1.
19 . The hydrogen storage system of claim 1 , wherein in said alloy composition further comprises about 1.0-10.0 at % total of at least one element selected from the group consisting of Ba, Co, Cu, Cs, K, Li, Mm, Mo, Na, Nb, Ni, Rb, Ta, Tl, and W (where Mm is mischmetal).
20 . The hydrogen storage system of claim 1 , wherein said thermally conductive compartmentalization network is fabricated by a 3D printing process.
21 . The hydrogen storage system of claim 1 , wherein both said external pressure containment vessel and said thermally conductive compartmentalization network are fabricated by a 3D printing process.
22 . The hydrogen storage system of claim 1 , wherein both said external pressure containment vessel and said thermally conductive compartmentalization network are fabricated simultaneously as a single unit by a 3D printing process.
23 . The hydrogen storage system of claim 22 , wherein said 3D printing process comprises deposition by Selective Laser Melting (SLM) and/or Direct Metal Laser Sintering (DMLS).
24 . The hydrogen storage system of claim 1 , wherein said thermally conductive compartmentalization network is fabricated by a 3D metal printing process, in which a highly thermally conductive printed metal is selected from the group consisting of: aluminum, aluminum alloys, copper, copper alloys, magnesium and magnesium alloys.
25 . The hydrogen storage system of claim 24 , wherein said 3D metal printing process comprises deposition by Selective Laser Melting (SLM) and/or Direct Metal Laser Sintering (DMLS).
26 . A method of fabricating said hydrogen storage system of claim 1 , comprising:
fabricating said thermally conductive compartmentalization network disposed within said external pressure containment vessel via a 3D printing process; and
depositing said hydrogen storage alloy within said hydrogen storage alloy containment vessel.
27 . The method of claim 26 , further comprising fabricating both said external pressure containment vessel said 3D printing process.
28 . The method of claim 26 , wherein both said external pressure containment vessel and said thermally conductive compartmentalization network are fabricated simultaneously as a single unit by said 3D printing process.
29 . The method of claim 27 , wherein said 3D printing process comprises deposition by Selective Laser Melting (SLM) and/or Direct Metal Laser Sintering (DMLS).
30 . The method of claim 26 , further comprising fabricating said thermally conductive compartmentalization network by said 3D printing process, in which a highly thermally conductive printed metal is selected from the group consisting of: aluminum, aluminum alloys, copper, copper alloys, magnesium and magnesium alloys.
31 . The method of claim 30 , wherein said 3D printing process comprises deposition by Selective Laser Melting (SLM) and/or Direct Metal Laser Sintering (DMLS).