Lifetime Concepts for Hydrogen Applications

We conduct research into methodologies and solutions to ensure and improve the resource efficiency of hydrogen infrastructure components. For our clients, we determine materials properties under real-world operating conditions, perform failure analysis for hydrogen-induced component failure, develop service life predictions, and establish design guidelines for components exposed to hydrogen.

In our integrated laboratory, we use experimental characterization combined with multiscale simulation to map end-to-end evaluation chains of materials samples across various scales, all the way up to the component level. We examine hydrogen as a pure substance, but also in humid environments, as a component of ammonia, or in its form derived from other media.

Our fields of application

In these fields of application, we identify materials science challenges faced by industrial companies—challenges where our expertise can make a particularly valuable contribution and deliver real benefits to our customers. This is where we can best leverage our strengths. We are uniquely positioned to provide the best solutions to the materials science questions associated with these challenges.

We can assist you in these application fields

New territory: hydrogen technology

Adapting products and systems for use in hydrogen technologies is a challenging project for many companies. This involves issues related to materials science, safety, service life, and compliance with norms and standards. Knowledge of materials regarding the effects of hydrogen is often incomplete. We help structure and prioritize key action items and fill information and knowledge gaps. We facilitate an efficient entry into the field of hydrogen technology.

Hydrogen readiness of components

Designing components for contact with hydrogen requires an assessment of the materials used in contact with (pressurized) hydrogen and of diffusion during component operation. The effects of operating conditions—such as temperature, pressure, and mechanical stress—on hydrogen sensitivity must be taken into account. We have the appropriate testing methods and can provide guidance on the application of hydrogen-specific standards.

Manufacturing factors affecting H2 components

Manufacturing technology plays a key role in determining how well a component performs in a hydrogen environment. Welds can act as critical weak points due to changes in microstructure and residual stresses. Defects and microcracks resulting from manufacturing and surface treatment can lead to increased local hydrogen concentrations and, consequently, damage. Heat treatments also influence susceptibility to hydrogen embrittlement. In additive manufacturing, porosity and inhomogeneity pose risks. We evaluate and optimize all types of manufacturing processes.

Service life and failure probability

The basis for predicting the safety, reliability, and service life of components in contact with hydrogen lies in high-quality materials data combined with knowledge of real-world operating conditions and reliable information such as stress states. Valid predictions regarding (remaining) service life and failure risks require robust damage and crack propagation models. We develop and adapt the appropriate prediction models to your specific application.

Hydrogen-induced defects and damage

To investigate hydrogen-induced damage to components, fracture surfaces are examined and hydrogen concentrations are measured. Microstructural weaknesses, hydrogen-assisted crack growth, and the causes of fracture can be determined under laboratory conditions. We reproduce the relevant damage mechanisms and derive measures to prevent them.

© Fraunhofer IWM, Photo: Kai-Uwe Wudtke
Dynamic fatigue test on a hollow specimen with hydrogen loading at high temperature using induction heating.

Determination of materials parameters under real-world operating conditions

We determine the materials parameters in high-pressure hydrogen required for your service life predictions using our testing facilities under conditions ranging from low to very high hydrogen pressures and from very low to very high temperatures.

Understanding the interactions between hydrogen and complex metallic structures

We study the interactions between hydrogen and metalin order to both understand the underlying mechanisms and make them predictable. This enables us to support our project partners in developing hydrogen barrier layers, optimizing manufacturing processes, and designing components for hydrogen applications.

© FraunhoferIWM
Schritte des Wasserstofftransports von der Gasphase in den gelösten Zustand im Metallgitter und die Diffusion in Bereiche mit hoher Spannung, wie Rissspitzen und Defekten.

Development of models for predicting service life

Our goal is to increase resource efficiency in the design of components throughout the hydrogen value chain. To this end, we are further developing empirical and physical models to improve the accuracy of service life predictions. We simulate the influence of hydrogen on materials properties across different scales—from the atomic scale, through the mesoscale (microstructural components), to the component level. From this, we derive insights into how hydrogen influences crack initiation and crack propagation in specific components during operation.

© Fraunhofer IWM, Foto: Kai-Uwe Wudtke
Eigenbau eines Wasserstoffautoklaven für Risswachstumsversuche.

Development of cost-effective testing methods

To economically characterize materials in contact with hydrogen, we develop hydrogen testing systems in various sizes that allow us to simulate the stress conditions encountered in different applications in a targeted and practical manner.

We perform materials characterization under hydrogen exposure on micro-, meso-, and macroscale samples, depending on the application, to identify factors relevant to damage in your components.
We combine experimentation, simulation, and analysis to specifically detect local materials properties and thereby create opportunities for materials optimization.
We design and build custom test setups to determine materials properties in interaction with hydrogen and specific operating conditions tailored to our customers’ needs.
We possess comprehensive expertise in standards, their application, and further development. Using this knowledge, we help determine the appropriate materials parameters and design their structures.
We investigate the formation of hydrogen in manufacturing processes and how to manage it in order to derive concrete countermeasures against hydrogen embrittlement.
We develop service life concepts for hydrogen applications to mathematically elucidate damage mechanisms and derive computer-aided measures to increase the service life of your components.
Several groups at Fraunhofer IWM are working on materials science challenges in hydrogen technologies. We will assemble the right team for your specific problem.
- We determine local mechanical properties and investigate local damage behavior on defects such as grain boundaries. To do this, we extract meso- and micromechanical samples, e.g., from welds, and test them in a hydrogen autoclave at pressures up to 100 bar.
- We conduct hydrogen tribology and investigate the influence of hydrogen on bearings and seals in tribological systems.
- We develop hydrogen barrier layers and measure hydrogen permeation.
- We demonstrate how guidelines on fatigue behavior and fracture mechanics must be applied and extended in a hydrogen environment.
- We develop and use atomistic models to investigate the behavior of hydrogen at the atomic level within the materials.

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Publications on Lifetime Concepts for Hydrogen Applications

Articles in journals, books, and conference proceedings, as well as dissertations and project reports...