Prevention and Monitoring – Keys to Safe Hydrogen Use
Therefore, preventing hydrogen embrittlement begins with material selection. Currently, steel-processing companies can refer to the U.S. standard SAE J2579, which defines clear criteria for the use of materials in hydrogen applications. The German Federal Ministry of Economics has also recognized the importance of uniform standards and commissioned a "Standardization Roadmap for Hydrogen Technologies." "Without standards, the interaction of the supply and value chain cannot function smoothly," emphasizes Werner Hannig.
Since the time between hydrogen uptake and damage often takes days or even months, prevention plays a key role. Various technical options are available for this.
- Mechanical galvanizing instead of classical galvanization
- Special surface coatings such as Dacromet or Geomet
- Alternative joining technologies like laser or TIG welding
- Adapted heat treatment processes with precise temperature control
According to Wackermann et al., targeted heat treatment has proven particularly effective. The so-called stress relief annealing at 200-230°C not only reduces critical residual stresses in the material but also tempers the highly distorted, freshly formed martensite. For high-strength steels, hydrogen baking is also essential, a process that removes dangerous diffusible hydrogen from the component.
Heat treatment is particularly important after galvanic processes. The temperature should be between 200°C and 230°C, with duration between 2 and 24 hours. It is crucial that the treatment occurs within four hours after galvanization – ideally even within the first hour.
Prevention also includes monitoring hydrogen-carrying systems. This is typically done through regular mechanical and technological material testing. Testers look for changes in ductility and possible reduction in uniform elongation and elongation at break. Standard ISO 15330 defines the standard procedure: components are exposed to a defined tensile stress for at least 48 hours and examined for crack formation.
Outlook: Hydrogen Needs New Standards
Given the numerous national hydrogen strategies that have been adopted around the globe for about five years, it's clear: the safe handling of the gas will become a key competency of the pipe and pipe processing industry in the coming years. This affects not only the planned development of a network of hydrogen pipelines and storage facilities but also numerous industrial applications – from heavy industry to mobility. Hydrogen embrittlement will remain a particular challenge, as it poses an enormous safety risk if not prevented.
Uniform international standards will play a central role. The "Standardization Roadmap for Hydrogen Technologies" initiated by the Federal Ministry of Economics is a first step, but there is still a long way to go before implementing the goals formulated therein. The industry needs clear guidelines for material selection, testing procedures, and maintenance intervals.
The wire & Tube 2026 will reflect this development: visitors can learn about the latest developments in materials technology, innovative testing methods, and forward-looking coating technologies. The exhibition's broad spectrum of offerings – from pipe materials and testing technology to complete system solutions – provides a thorough overview of the current state of the art.
For more information about wire & Tube 2026, visit www.tube.de
Sources
- Wackermann, K., Schweizer, F., Pfeiffer, W.: Hydrogen Embrittlement of Metallic Materials: Adsorption, Diffusion and Material Properties. gwf Gas+Energie, 2-3/2019
- Hannig, W.: Hydrogen Embrittlement in Stainless Steel Tubes: Standards and Specifications are Crucial. Interview. gwf Gas + Energie 01-02|2025
- Bossard Group: Hydrogen Embrittlement. White Paper, Zug 2020
- Federal Ministry for Economic Affairs and Climate Action (BMWK): Standardization Roadmap Hydrogen Technologies, Berlin 2024