Objective This study aims to investigate the influences of aluminum alloy lining structure parameters on the overall fatigue performance of type Ⅲ hydrogen cylinder, and obtain the optimal design scheme of lining which can improve the long-term performance of gas cylinder.

Methods Based on orthogonal test and numerical simulation, the fatigue life of composite material gas cylinder is calculated by Brown-Miller algorithm. Through correlation analysis, the influences of cylinder wall thickness, length-diameter ratio and head ellipsoid ratio on fatigue performance are comprehensively evaluated, and the main factor is confirmed to be cylinder wall thickness. Based on Goodman average stress correction equation, the variation of lining stress amplitude with the increase of wall thickness is analyzed. The optimal design is verified by the normal temperature pressure cycle test.

Results The actual fatigue life of cylinders is in good agreement with the simulation results, and the final cycle times are 5.7%, which is different from the simulation results. The fatigue failure position of gas cylinder appears in the lining cylinder body, and the fatigue failure of aluminum alloy lining is earlier than that of fiber winding layer.

Conclusions The fatigue life of the optimized composite material gas cylinder is 44.7% longer than that of the standard. It is feasible to optimize the lining structure parameters of type Ⅲ hydrogen cylinder by orthogonal test.