This study investigates the hydrogen permeability of injection-molded polyamide 6 (PA6) nanocomposites reinforced with organo-modified montmorillonite (OMMT) at varying concentrations (1, 2.5, 5, and 10 wt. %) for potential use as Type IV composite-overwrapped pressure vessel (COPV) liners. While previous work examined their mechanical properties, this study focuses on their crystallinity, morphology, and gas barrier performance. The precise inorganic content was determined using thermal gravimetry analysis (TGA), while differential scanning calorimetry (DSC), wide-angle X-ray diffraction (WAXD), and scanning electron microscopy (SEM) were used to characterize the structural and morphological changes induced by varying filler content. The results showed that generally higher OMMT concentrations promoted γ-phase formation but also led to increased agglomeration and reduced crystallinity. The PA6/OMMT-1 wt. % sample stood out with higher crystallinity, well-dispersed clay, and low hydrogen permeability. In contrast, the PA6/OMMT-2.5 and -5 wt. % samples showed increased permeability, which corresponded to WAXD and SEM evidence of agglomeration and DSC results indicating a lower degree of crystallinity. PA6/OMMT-10 wt. % showed the most-reduced hydrogen permeability compared to all other samples. This improvement, however, is attributed to a tortuous path effect created by the high filler loading rather than optimal crystallinity or dispersion. SEM images revealed significant OMMT agglomeration, and DSC analysis confirmed reduced crystallinity, indicating that despite the excellent barrier performance, the compromised microstructure may negatively impact mechanical reliability, showing PA6/OMMT-1 wt. % to be the most balanced candidate combining both mechanical integrity and hydrogen impermeability for Type IV COPV liners.

In our study, we compare the surface modifications of coarse HDPE surface induced by atmospheric air plasma, CO2 laser, and flame treatments. An order of WCA decrease of air plasma>flame>CO2 laser methods was detected. The improvement in adhesion strength measured 5 days after the activations followed the same trend. FT-IR and EDS proved that different oxygen compounds were formed after treatments, resulting in increased polar component of the total surface energy. Flame activation showed a saturation character regarding the O-moiety. Hydrophobic recovery showed a linear behavior, with a larger decreasing slope for the polar component than the total surface energy. Plasma treatments induced higher recovery rate; however, restore was not complete here either. The effects of the different CO2 irradiation intensities were nonlinear; SEM and roughness measurements revealed surface ablation or structure formation on the different samples, while after plasma and flame treatment a hilly microtexture appeared. With different mechanisms and intensities, all the tested methods are suitable for increasing the adhesion strength on HDPE surfaces.

This study focuses on polyamide 6/organo-modified montmorillonite (PA6/OMMT) nanocomposites as potential liner materials, given the growing interest in enhancing the performance of type IV composite overwrapped hydrogen storage pressure vessels. The mechanical properties of PA6/OMMT composites with varying filler concentrations were investigated across a temperature range relevant to hydrogen storage conditions (−40 °C to +85 °C). Liner collapse, a critical issue caused by rapid gas discharge, was analyzed using an Ishikawa diagram to identify external and internal factors. Mechanical testing revealed that higher OMMT content generally increased stiffness, especially at elevated temperatures. The Young’s modulus and first yield strength exhibited non-linear temperature dependencies, with 1 wt. per cent OMMT content enhancing yield strength at all tested temperatures. Dynamic mechanical analysis (DMA) indicated that OMMT improves the storage modulus, suggesting effective filler dispersion, but it also reduces the toughness and heat resistance, as evidenced by lower glass transition temperatures. This study underscores the importance of optimizing OMMT content to balance mechanical performance and thermal stability for the practical application of PA6/OMMT nanocomposites in hydrogen storage pressure vessels.