Materials & Design Review of HPV for Space Applications

Eivazi Bagheri, Hadi; Salek Rahimi, Mohammad Javad; Farkhondeh, Amir Hesam; Ziae Azar, Adel

doi:10.22075/imcf.2026.39337.1049

Materials & Design Review of HPV for Space Applications

Document Type : Review article

Authors

¹ faculty of Advance materials and Nano Technology , imam hossein University

² University of Tabriz, Faculty of Mechanical Engineering

³ Department of Mechanical Engineering, Babol Noshirvani University of Technology, Babol

10.22075/imcf.2026.39337.1049

Abstract

High-Pressure Vessel (HPV) systems are crucial for space missions, enabling the safe storage of cryogenic fuels, oxidizers, and life-support media under extreme conditions. This review examines the latest materials, design parameters, and operational challenges of these vessels, with a focus on cryogenic, hydrogen, oxygen, hybrid, and life-support tanks. Special attention is given to the evolution of materials, from metallic alloys to advanced composites like CFRPs, graphene, and CNTs, achieving up to 50% weight reduction and improved thermal and mechanical performance. Key design parameters such as pressure tolerance (up to 700 bar), thermal management (TM) (using MLI and PCMs), and structural health monitoring (SHM) are discussed in the context of long-duration missions. The integration of artificial intelligence for predictive failure analysis and optimization is also explored, outlining a revolutionary pathway for next-generation, self-healing tanks. This review charts an transformative roadmap for the next generation of High-Pressure Vessel (HPV) technologies essential for sustained space exploration.

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