Hydrogen Adoption Across Industries: Materials Challenges & Engineering Solutions
A series of lunchtime webinars exploring materials behaviour, testing technologies, engineering design, and deployment challenges for hydrogen systems across aerospace, energy, and industrial sectors.
As industries transition to a hydrogen economy, fatigue and durability present significant engineering challenges across production, storage, transportation and end-use applications. This webinar series will explore the multifaceted nature of hydrogen adoption, examining fatigue because of mechanical, thermal and pressure cycles, as well as the pervasive issue of permeation. Experts will discuss critical topics such as hydrogen embrittlement, the challenges of testing and validation, and the infrastructure hurdles facing key sectors. Through a cross-industry perspective, we will highlight current barriers and explore innovative solutions to ensure the long-term reliability and viability of hydrogen technologies.
Webinar 1 - 22 April 12.30-1.30pm
Materials Challenges for Hydrogen in Aerospace – Louise Gale, Rolls-Royce
As part of the drive for Net Zero emissions by 2050 aerospace OEMs are in the early stages of development of hydrogen fuelled gas turbines engines. As part of this Rolls-Royce is actively developing hydrogen gas turbine engine technology. Storing, pumping, metering and combustion of H2 requires innovative technologies which are undergoing integration and validation through a demonstrator project, which involves the modification of a Pearl15 gas turbine engine for ground testing with gaseous and cryogenic liquid hydrogen. The introduction of hydrogen as the primary fuel introduces novel failure modes that are driven by materials challenges including hydrogen embrittlement, increased water vapour environmental attack and materials cryogenic performance. There is the need for development of methodologies to incorporate these materials risks into component integrity assessments to ensure safe and reliable operation of engines. This talk will present the materials challenges and opportunities presented by the use of hydrogen fuel in aerospace compared with more established hydrogen industries. It will also provide insights into Rolls-Royce’s preliminary work in materials modelling and testing & test method development to address these challenges.
BIOGRAPHY
Understanding Hydrogen Embrittlement: From Lab-scale Insights to Real-world Applications – Alfredo Zafra, University of Oxford
Hydrogen embrittlement (HE) remains a critical challenge in the deployment of hydrogen technologies, particularly affecting high-strength alloys used in energy, transportation, and infrastructure sectors. Despite over a century of research, the complex mechanisms of HE continue to hinder the development of reliable hydrogen systems. At the Mechanics of Materials Lab, University of Oxford, our research focuses on elucidating the fundamental processes of HE through advanced experimental techniques and multi-scale modelling. We investigate hydrogen interactions at the microstructural level, aiming to understand how hydrogen affects material properties and contributes to failure. Our work includes developing predictive models that integrate experimental data to simulate hydrogen-induced degradation under various service conditions. This presentation will provide an overview of our group’s approach to studying HE, highlighting recent findings and their implications for material design and structural integrity. We will discuss how our integrated methodology contributes to the development of hydrogen-resistant materials and supports the safe implementation of hydrogen technologies across industries.
BIOGRAPHY
Webinar 2 - 30 April 12.30-1.30pm
Developing and Validating Test Machines for Hydrogen Applications: Enabling Safe, Reliable Testing Across Sectors and Supply Chains – Vicki Wilkes, Darvick
Hydrogen is a key enabler in the transition to net-zero, with applications spanning transport, aerospace, and heavy industry. However, its use—especially under high-pressure, high-temperature, or cryogenic conditions—introduces complex material and safety challenges. Accurate assessment of mechanical performance in these environments is essential to generate reliable data for design databases, predictive models, and safety validation.
Despite growing demand, there remains a recognised shortfall in UK-based, commercially available, test capabilities for hydrogen environments with the required scope, accuracy, reliability and repeatability.
This presentation outlines the development and validation of test machines and methods engineered to address this gap. We will explore the technical and commercial challenges encountered and share some of the innovative solutions we have developed, as well as the areas where ongoing cross-sector and supply chain engagement would help to support the safe, rapid, and robust adoption of hydrogen as a fuel.
BIOGRAPHY
Cryo-mechanical Testing for Hydrogen Adoption: Challenges in Fusion and Aerospace – Khurram Amjad, UK Atomic Energy Authority
As hydrogen becomes central to zero-emission energy strategies, both the nuclear fusion and aviation sectors are advancing their use of cryogenic hydrogen technologies. These developments introduce demanding requirements for structural materials, which must maintain integrity under extreme cryogenic and hydrogen-rich conditions. Meeting these challenges calls for robust solutions across the technology lifecycle—from accelerated material qualification and innovative component design to in-service structural health monitoring in complex, multi-physics environments. This talk highlights the overlapping cryo-mechanical testing needs in fusion and hydrogen-powered aviation, with a focus on ensuring structural integrity through advanced strain measurement techniques.
BIOGRAPHY
Webinar 3 - 19 May 12.30-1.30pm
Design Methodology for Hydrogen Pressure Systems – Charlie Hutchings, Frazer-Nash Consultancy
Hydrogen embrittlement effects typically manifest as a reduction in fatigue and fracture resistance. In the design of pressure systems the effects of hydrogen embrittlement must be considered, particularly with respect to fatigue life. Currently, the only accepted and standardised approach to calculating fatigue life for pressure systems in hydrogen service is fracture mechanics. Developments in the basis for materials, joining, and inspection requirements specific to hydrogen pressure systems will be presented. Anticipated, code updates to facilitate a total life fatigue assessment for hydrogen pressure systems will be discussed. Factors that have been shown to affect hydrogen embrittlement such as fatigue frequency, gaseous impurities, and surface condition, are not currently considered in the design codes. Finally, this presentation will look at the current guidance on how and when to invoke service requirements.
BIOGRAPHY
Decarbonising the Skies: A National Perspective on Hydrogen Challenges and Capabilities – Fran Synnott, Aerospace Technology Institute
The Aerospace Technology Institute’s (ATI) FlyZero project concluded that liquid hydrogen is the most viable zero-carbon emission fuel with the potential to scale to larger aircraft, presenting a significant opportunity for decarbonising aviation by 2050. Its adoption requires coordinated development of infrastructure, technologies, and skills across government, industry, and academia. The ATI brings a unique perspective on the challenges of hydrogen integration into the aerospace sector in the broader framework of national initiatives. Through its Hydrogen Capability Network, the ATI promoted engagement and collaboration within industry, academia, regulators and liquid hydrogen suppliers to identify challenges and coordinate research. This talk will discuss the current capabilities in hydrogen-focused projects at the national level and the ongoing development efforts supported by ATI to advance potential solutions and recommend actions to enable zero-carbon emission flight.
BIOGRAPHY
Webinar 4 - 21 May 12.30-1.30pm
Hydrogen Fueled Internal Combustion Engines for the Machinery & Equipment Sector – Richard Doyle, JCB
JCB has developed, certified, and released to market, a hydrogen-fueled Internal Combustion Engine (ICE). This powertrain technology is a relevant and practical zero-emissions solution for construction, mining and agricultural equipment.
This talk will explain the advantages of H2-ICE verses alternative zero carbon emitting technologies for our sector. In addition, the remaining challenges to the success of this technology in our industrial sector will be discussed.
What are the material challenges that had to be overcome, to utilise existing ICE technology with a gaseous hydrogen fuel? And what material science questions remain un-answered in order to develop H2-ICE technology further into higher power engine variants?
These materials challenges will be presented as an opportunity for the academic and commercial test worlds of materials science to assist in the industrial advancement of a working green powertrain solution.
BIOGRAPHY
Slowing the Unstoppable – Can we really avoid hydrogen entering materials? – Francesco Fanicchia, Cranfield University
Hydrogen permeation through structural materials can lead to hydrogen damage in both metallic and composite systems and therefore poses a significant challenge to the development and long-term reliability of hydrogen-based energy systems. This talk examines the mechanisms of hydrogen transport in metals and polymers, the methodologies used to quantify permeation rates, and the limitations of current testing standards, particularly for metallic systems. It also discusses recent advances in mitigation strategies, including hydrogen permeation barrier (HPB) coatings and microstructural trapping approaches, aimed at reducing steady-state flux. While complete prevention of hydrogen ingress is not feasible, understanding and managing permeation is essential to ensure the safe deployment of hydrogen technologies across aerospace, energy, and transport sectors.
BIOGRAPHY