1st Conference on Hydrogen in Materials Science and Engineering - H2 MSE
Lecture
12.02.2025
The role of elastomeric sealing applications in high-pressure H2 applications: Progress in material and test method development
WB

Dr. Winoj Balasooriya

SCIOFLEX Hydrogen GmbH

Balasooriya, W. (Speaker)¹; Schrittesser, B.¹
¹SCIOFLEX Hydrogen GmbH, Mattersburg (Austria)
Vorschau
19 Min. Untertitel (CC)

Hydrogen is receiving a lot of attention as a clean energy carrier as well as a viable and cost effective solution for renewable energy storage. Pressurized H2 gas has an advantage over other forms of storage due to its high efficiency, convenience and technological maturity. Elastomeric materials, particularly rubber O-rings, play a critical role in sealing components at various stages of hydrogen systems, including distribution, storage, dispensing and on-board use in FCVs. These materials are expected to provide high durability and maintain seal integrity over long periods of time. However, degradation of elastomers can lead to increased permeation or premature failure due to mechanical damage, limiting their intended use. H2 leakage throughout the value chain is a safety concern and an economic loss. A critical study shows that "Green H2" can only mitigate atmospheric methane if hydrogen losses throughout the value chain are less than 9%, or "Blue H2" less than 1% of the H2 produced, as the leaked gas is responsible for the indirect GHG effect. Therefore, the development of novel elastomer materials optimized for hydrogen conditions, along with experimental techniques to accurately assess their properties, is of utmost importance. All elastomers allow hydrogen gas to dissolve and permeate based on their gas transport properties. Rapid gas decompression (RGD) is a major failure mode that threatens elastomer components due to gas dissolution under stress and subsequent sudden release during compression-decompression routines. However, to date, there are no standards for testing elastomeric materials for hydrogen environments and no material specifications to guide industry on acceptable materials for specific conditions. Therefore, identification of industrial gaps and development of materials and test methods is the way forward. SCIOFLEX Hydrogen GmbH is building an in-situ hydrogen testing system capable of tensile, fatigue, bending and fracture mechanics tests up to 40 MPa H2 gas. The hollow specimen approach for polymeric materials is being tested, which helps to mitigate the drawbacks of conventional H2 autoclave testing systems. 

Abstract

Abstract

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