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Liquid hydrogen (LH₂) produced from renewable energy sources is now recognised as the most promising source of energy to achieve zero carbon emission travel. Thin walled aluminium vessels, lining carbon fibre reinforced polymer (CFRP), could offer a lightweight solution for storing LH₂. However, there is an increasing need to develop a reliable, automated, consistent and high quality welding process for thin-walled aluminium liners for large-scale manufacture of hydrogen storage vessels. The present investigation focuses on the development of a stationary shoulder-micro friction stir welding (SS-μFSW) procedure for the manufacture of aluminium liners with sub-millimetre thickness. Using AA2024-T3 flat-sheet coupons of 0.8mm in thickness, a series of weld trials was undertaken to assess the mechanical and microstructural properties of the welds via metallography and tensile testing at ambient and cold temperatures. Two technology demonstrators consisting of thin thickness half shells joined by SS-μFSW in a seam welding configuration was also demonstrated as part of the requirements for Technology Readiness Level 3.

13th International Symposium, 21-23 May 2024, Session 10: Techniques III, Paper 02