TY - CONF A1 - Theiler, Géraldine T1 - Tribological behavior of polymeric materials in hydrogen N2 - In this talk, an overview of BAM research activities related to Hydrogen is given with a brief presentation of the Competence Center H2Safety@bam. The second part focuses on current projects dealing with the tribological behavior of polymeric materials in Hydrogen. In particular, results regarding the performances of PTFE -free and sustainable materials are given and promising candidates are suggested along with friction mechanisms. T2 - International Hydrogen Energy Development Forum & HYDROGENIUS SYMPOSIUM 2025 CY - Kyushu, Japan DA - 17.12.2025 KW - Hydrogen KW - Friction KW - Wear KW - PTFE-free KW - Sustainable material PY - 2025 AN - OPUS4-65364 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Grimault de Freitas, Tomás T1 - From Research to a Standard: The Hollow Specimen Technique for High-Pressure Hydrogen Gas Testing N2 - As the world moves towards a decarbonised economy, the demand for sustainable and low-carbon alternatives is growing rapidly. Hydrogen has an important role to play in this transition, but in order to make the most of hydrogen as an energy carrier, a comprehensive understanding of its impact on the integrity of structural materials is necessary. Metallic materials, mainly steels, are the most commonly used structural materials in various components throughout the hydrogen supply chain. Ensuring their sustainable and safe use in hydrogen technologies is a crucial factor in the development of the hydrogen economy. This is particularly important since hydrogen can promote crack formation and ultimately lead to premature failure in these materials when combined with mechanical load. This process is commonly known as Hydrogen Embrittlement and can occur in almost all the steels used for the hydrogen technologies. Extensive materials qualification is required for the rapid implementation of hydrogen technologies, however, most accepted, and standardised test methods for determining the effect of gaseous hydrogen on metallic materials describe complex and costly procedures that are only available to a very limited extent worldwide. The hollow specimen technique is a simple and economical method that has the potential to overcome the limitations of the current methods and complement them for qualifying metallic materials under high-pressure hydrogen gas. Unlike the conventional autoclave technique, this method requires significantly lower amounts of hydrogen, resulting in fewer safety measures and no need for complex equipment or a specialised laboratory. The technique's low investment and testing costs, simple operation, and shorter testing time make it an optimal for widespread use around the world, thereby increasing the output of results. Initial studies have demonstrated the feasibility of assessing hydrogen effects in metallic materials using the hollow specimen technique. This led to the establishment of an ISO committee to standardise the method. However, there are open questions that currently prevent the technique from being standardised for hydrogen testing. These open questions relate to specimen geometry, inner hole surface and gas quality and are being addressed in the H2HohlZug project, of which the overall aim is to systematically close the gaps towards a standard. This contribution presents the structure and milestones of the project, followed by initial results. T2 - CETIM Workshop Technique H2 CY - Nantes, France DA - 11.12.2025 KW - Hydrogen KW - Hydrogen Embrittlement KW - Hollow Specimen Technique KW - High-Pressure Gaseous Hydrogen KW - TransHyDE KW - H2HohlZug KW - Standardisation PY - 2025 AN - OPUS4-65103 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Ebell, Gino T1 - Einfluss von Korrosionsprozessen auf die Verbundfestigkeit Feuerverzinkter Betonstähle in der Erstarrungsphase von Beton N2 - Die Wechselwirkung von hoher Alkalität und feuerverzinktem Betonstahl in der Frischbetonphase generiert einen Störung in der Verbundzone. diese Störung basiert sowohl auf der Wasserstoffentwicklung in der Frischbetonphase bis zur diffusionskontrollierten Decksschichtbildung als auch auf die erstarrungsverzögernde Wirkung von Zinkionen auf die CSH-Phasenbildung. Diese werden zwangsläufig infolge anfänglicher starker Korrosionsprozesse frei, und reichern sich in der Verbundzone an. Hier kann es beim normgerechten Ausschalen nach 24h zu weiteren Störungen des Haftverbundes kommen das davon Auszugehen ist das die Erstarrung der CSH-Phasen in der Verbundzone noch nicht begonnen hat. T2 - Forschungsbeiratssitzung der Forschungsvereinigung Feuerverzinkung CY - Darmstadt, Germany DA - 04.12.2025 KW - Korrosion KW - Verzinkter Betonstahl KW - Hydrogen PY - 2025 AN - OPUS4-65054 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - El Harrab, Hayat A1 - Askar, Enis A1 - Franken, T. A1 - Mauss, F. T1 - Experimental and Reaction Kinetic Study of Hydrogen Ignition Behavior at Ignition Limits N2 - The paper presents the results of the experimental and reaction kinetic investigation of hydrogen ignition at different pressures, highlighting its non-linear behaviour and effects of radical wall termination. The reaction kinetic simulation predicts the three characteristic ignition limits caused by radical and thermal auto-ignition and is in close agreement with the experimental measurements. The introduction of radical wall termination in the reaction mechanism allowed us to investigate the effect of the autoclave wall and vessel size on the hydrogen ignition behaviour. The first ignition limit is determined by the chain initiation reaction H_2+O_2→2 OH and shows a strong sensitivity towards wall termination of O, H and OH radicals. The third ignition limit is dominated by the reaction paths HO_2+HO_2→H_2 O_2+O_2 and H_2 O_2+M→2 OH+M which is why it shows a strong sensitivity towards wall termination of HO₂ and H₂O₂ radicals. The second ignition limit is influenced by the wall termination of O, H, OH, HO2 and H2O2 radicals. Increasing the radical wall termination rate by increasing the adsorption rate of the radicals at the wall leads to an increase of the auto-ignition temperature at the same pressure. T2 - 13th Mediterranean Combustion Symposium CY - Corfu, Greece DA - 01.06.2025 KW - Hydrogen KW - Auto-ignition Temperature KW - Radical Wall Termination Reaction KW - Ignition Limit PY - 2025 AN - OPUS4-64762 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Grimault de Freitas, Tomás T1 - Hollow Specimen Method for Tests in High-Pressure Hydrogen Gas: The Role of Strain-Rate and Surface Quality N2 - As the world moves towards a decarbonised economy, the demand for sustainable and low-carbon alternatives is growing rapidly. Hydrogen has an important role to play in this transition, but in order to make the most of hydrogen as an energy carrier, a comprehensive understanding of its impact on the integrity of structural materials is necessary. Metallic materials, mainly steels, are the most commonly used structural materials in various components throughout the hydrogen supply chain. Ensuring their sustainable and safe use in hydrogen technologies is a crucial factor in the development of the hydrogen economy. This is particularly important since hydrogen can promote crack formation and ultimately lead to premature failure in these materials when combined with mechanical load. This process is commonly known as Hydrogen Embrittlement and can occur in almost all the steels used for the hydrogen technologies. Extensive materials qualification is required for the rapid implementation of hydrogen technologies, however, most accepted, and standardised test methods for determining the effect of gaseous hydrogen on metallic materials describe complex and costly procedures that are only available to a very limited extent worldwide. The hollow specimen technique is a simple and economical method that has the potential to overcome the limitations of the current methods and complement them for qualifying metallic materials under high-pressure hydrogen gas. Unlike the conventional autoclave technique, this method requires significantly lower amounts of hydrogen, resulting in fewer safety measures and no need for complex equipment or a specialised laboratory. The technique's low investment and testing costs, simple operation, and shorter testing time make it an optimal for widespread use around the world, thereby increasing the output of results. Initial studies have demonstrated the feasibility of assessing hydrogen effects in metallic materials using the hollow specimen technique. This led to the establishment of an ISO committee to standardise the method. However, there are open questions that currently prevent the technique from being standardised for hydrogen testing. These open questions relate to specimen geometry, inner hole surface and gas quality and are being addressed in the H2HohlZug project, of which the overall aim is to systematically close the gaps towards a standard. This contribution presents the structure and milestones of the project, followed by initial results. T2 - HyLab | HyTalks CY - Online meeting DA - 12.11.2025 KW - Hydrogen KW - Hydrogen Embrittlement KW - Hollow Specimen Technique KW - High-Pressure Gaseous Hydrogen KW - TransHyDE KW - H2HohlZug PY - 2025 AN - OPUS4-64749 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kromm, Arne T1 - From the field to the lab and back: Evaluating the integrity of welded components using scaled experiments N2 - This contribution addresses the question of how the behaviour of complex parts or components in industrial practice can be simulated using simple welding experiments in the laboratory. It is demonstrated how so-called mock-ups can be utilised for this purpose. In particular, a test rig specially designed for scaled welding experiments is shown. It allows mechanical restraints and stiffnesses to be simulated, as well as typical welding process parameters and post weld heat treatments. Selected examples show how solidification crack growth during welding of high-strength steels can be quantified, under which conditions stress relaxation cracks occur during the heat treatment of heat-resistant steels, and how the integrity of pressurised hydrogen pipelines can be assessed during repair welding. T2 - 4th International Conference on Advanced Joining Processes 2025 CY - Coimbra, Portugal DA - 16.10.2025 KW - High strength steel KW - Stress relief cracking KW - Hydrogen PY - 2025 AN - OPUS4-64505 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kröll, Mirco T1 - Tribological performance of polymer compounds in gaseous hydrogen N2 - In this study, friction and wear of conventional and alternative high performance polymer compounds, typically used for components of compressors, were investigated in gaseous hydrogen and nitrogen up to 80 bar of gas pressure. The compounds used were a commercial PEEK matrix with 10 wt.% each of PTFE, graphite, and short carbon fibres, a PPS matrix with 10 wt.% each of PTFE and graphite, and an experimental PA12 matrix with PTFE chemically coupled with an oleyl alcohol. Due to the cylindrical shape of the polymer samples, the contact area and pressure change if wear occurs. Therefore, experimental results of pre-screening tests have been used as input for FEM and an analytical model to determine the decreasing contact pressure over time. Afterwards, the outcome of the models was used to determine the duration of the experiments to reach typical contact pressures of seals in hydrogen compressors. T2 - ASMET TriboCorrosion International Conference 2025 CY - Vienna, Austria DA - 23.10.2025 KW - Hydrogen KW - Polymer KW - Tribometer KW - Comparability KW - Harmonisation KW - Oil-coupled compounds KW - Coefficient of Friction KW - Wear KW - FAIR data KW - Standardisation KW - Tribology KW - Database KW - i-TRIBOMAT PY - 2025 AN - OPUS4-64473 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael A1 - Masoud Nia, Niloufar A1 - Nietzke, Jonathen A1 - Kannengiesser, Thomas T1 - Ti and Nb microalloying of HSLA steels and its effect on hydrogen diffusion and trapping N2 - Fine-grain, high-strength, low-alloy (HSLA) structural steels with yield strengths > 600 MPa are now the state of the art in construction applications such as mobile cranes and civil engineering. HSLA grades derive their strength from a combination of specific heat treatment and the underlying chemical composition. In this context, Ti or Nb are essential to obtain a fine-grained microstructure as well as the necessary carbides or nitrides for precipitation strengthening. In this context, the specific effect of Ti or Nb-rich compounds on hydrogen trapping and diffusion is well known for special laboratory cast alloys, but unknown for realistic steel compositions. For this reason, a series of S690Q-based alloys were synthesized, close to a real steel composition, but with well controlled Ti or Nb additions in different amounts. Specimens were obtained from these alloys by electrochemical discharge machining (EDM). The specimens were tested using the well-established electrochemical permeation technique. From the experimental results, the hydrogen diffusion coefficients and the analytical subsurface hydrogen concentration were calculated. In addition, the hydrogen trapping behavior at elevated temperatures was interpreted by thermal desorption analysis (TDA) using different heating rates of hydrogen charged samples. The results showed that in contrast to metallurgically "pure" laboratory cast alloys, realistic chemical compositions were similar in their hydrogen trapping behavior, despite some small differences. All investigated steel grades exhibited shallow and reversible hydrogen trapping, regardless of their chemical composition. Of course, the experiments only allowed the calculation of effective diffusion coefficients and trapping energies, which represent an average of the entire microstructure. Nevertheless, HSLA steels are typically joined by arc welding, which includes the risk of delayed hydrogen assisted cracking. From the point of view of welding practice, however, a more or less identical hydrogen diffusion behavior means that no special "metallurgically specific", justifiable measures need to be considered, despite the well-established processes such as "soaking" or dehydrogenation heat treatment. T2 - MPAC 2025 CY - Stuttgart, Germany DA - 06.10.2025 KW - HACC KW - Hydrogen KW - HSLA PY - 2025 AN - OPUS4-64337 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Component test for simulation of in-service welding on hydrogen pipelines N2 - Hydrogen is set as the energy carrier of tomorrow and most countries will achieve large-scale hydrogen transport through the conversion of the natural gas (NG) grid and the construction of new pipelines. The interaction between hydrogen and the pipeline materials differs fundamentally from that of NG, as hydrogen is readily absorbed into the material. Considering the possible hydrogen embrittlement (HE), the compatibility of the pipeline materials (low-alloyed steels with a wide strength/thickness range) must be investigated. However, pipelines require intervention for maintenance, repair, or grid expansion with welding on/onto the pipelines while in service, i.e. the well-known "hot tapping" and "stoppling". The challenges compared to NG can be broadly divided into the possible austenitization of the inner pipe material exposed to hydrogen and the welding itself. Both result in a significant increase in hydrogen solubility and could potentially pose challenges in terms of HE. Emphasis is placed on the word "could" because knowledge of "hot tapping" on hydrogen pipelines is scarce due a lack of service experience. To this end, this study proposes a concept for a component-like demonstrator with the objectives: (1) safe feasibility of "hot tapping" on pressurized model hydrogen pipeline sections, (2) facilitate ex-post sample extraction for the purpose of quantifying the absorbed hydrogen concentrations, and (3) ensure in-situ temperature measurement during welding to monitor the pipeline surface temperature. For safety reasons in the event of an unintentional "burn-through", a solid cylinder was inserted in the demonstrator to restrict the hydrogen gas volume to a small, pressurized layer. Reference pipeline surface temperature measurements were ensured on comparable, unpressurized geometries. The investigated range of welding conditions was investigated for representative material/thickness combinations (DN60 to DN300), suggesting the feasibility of the demonstrator for the determination of reliable in-service welding conditions for both installed and new pipelines for hydrogen service. T2 - 49th MPA Conference CY - Stuttgart, Germany DA - 06.10.2025 KW - Hydrogen KW - Pipeline KW - In-service welding KW - Component test PY - 2025 AN - OPUS4-64317 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Ekici, Nilsah T1 - Introduction of The SHIMMER Database for Safe Hydrogen Injection in The European Natural Gas Infrastructure N2 - An important step in the transportation strategy for hydrogen is its injection into the existing natural gas grid, which allows accelerating the transition to a low-carbon economy, in other words, hydrogen economy. The European Commission has established hydrogen roadmaps and strategies that emphasize the safe and efficient integration of hydrogen into the natural gas network to support this transition. In line with the objectives of the road map, several funded projects have been established, among others – the Safe Hydrogen Injection Modelling and Management for European Gas Network Resilience (SHIMMER) project. One of the main goals of this project is establishing a database containing a comprehensive repository of information regarding materials, standards, European pilot projects, and operational conditions parameters for the European gas network gathered from open sources as well as transmission and distribution system operators participating in the project. The SHIMMER database has an extensive structure consisting of 262 pipeline entries, each with details such as length, design pressure, inner diameter, and installation year and more. The following contribution elaborates on how the SHIMMER database was established as reliable source of information to be available for the public. The database allows consistent assessments of hydrogen compatibility across different countries, offering a structured framework to help overcome the challenges inherent to the assessments of the components for the injection of hydrogen across Europe. Further, the SHIMMER database provides a valuable information source for future research on the European gas networks. T2 - ICHS 2025 CY - Seoul, South Korea DA - 22.09.2025 KW - Database KW - Hydrogen KW - Gas Grid KW - Low-carbon KW - Pipeline Steel PY - 2025 AN - OPUS4-64288 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Hydrogen trap characterization in 200 and 1,000 bar charged CoCrNi medium entropy alloy compared to steel AISI 316L N2 - Multiple principal element alloys (MPEAs) represent a new class of metallic materials. MPEAs, such as the CoCrNi medium entropy alloy (MEA), have attracted considerable research attention as potential materials to replace, for example, austenitic steels in high-pressure hydrogen environments. Due to the relatively new alloy concept, studies on the specific hydrogen diffusion and trapping behavior of high-pressure hydrogen-charged CoCrNi MEAs are rare so far. For this reason, a CoCrNi-MEA was investigated and compared to an austenitic stainless steel, AISI 316L. Both materials were subjected to high pressure hydrogen loading for two different pressures: 200 bar and 1,000 bar. After charging, thermal desorption analysis (TDA) was used with three heating rates from 0.125 K/s to 0.500 K/s to clarify the specific hydrogen desorption and trapping behavior. To the best of our knowledge, this study is the first to characterize hydrogen diffusion and trapping in 1,000 bar high-pressure charged CoCrNi. For this purpose, the underlying TDA spectra were analyzed in terms of peak deconvolution into a metallurgically justifiable number of defined peaks. The individual peak temperatures and activation energies “EA” were calculated. The following conclusions can be drawn from the results obtained: (1) Exposure to 200 bar or 1,000 bar leads to an increase in hydrogen absorption, regardless of the material investigated, expressed by a significantly increased desorption rate at 1,000 bar. However, the effusion peaks typically occur only at high temperatures. The (2) TDA showed that a four-peak deconvolution scenario was sufficient to describe the trapping behavior and the "EA" indicated the dominance of irreversible traps. In addition, the average trapping energy is higher than in the 316L. The (3) charge pressure related hydrogen solubility was in the order of: CoCrNi-MEA < 316L for both pressures and (4) charging at 1000 bar results in an average concentration of 49 wt.ppm (CoCrNi-MEA) and > 75 wt.ppm (316L). In summary, the CoCrNi-MEA was characterized by a reduced solubility, but very deep entrapment compared to the 316L. For this reason, further application potentials of the MEA may arise. T2 - FEMS Euromat 2025 - 18th European Congress and Exhibition on Advanced Materials and Processes CY - Granada, Spain DA - 15.09.2025 KW - Medium entropy alloy KW - Hydrogen KW - Trapping KW - Diffusion KW - High-pressure charging PY - 2025 AN - OPUS4-64160 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Component test for the assessment of in-service welding on/onto pressurized hydrogen pipelines N2 - Hydrogen is the energy carrier of tomorrow and requires a reliable large-scale transport infrastructure. In addition to new pipelines, the conversion of existing natural gas (NG) pipeline grids is an essential part. The transport of hydrogen is fundamentally different from that of NG, as hydrogen can be absorbed into the pipeline material. Given the effects of hydrogen embrittlement, the material compatibility (low alloy steels in a wide range of strengths and thicknesses) must be investigated. However, pipelines e.g. require maintenance or the need for installation of additional outlets with the necessity of welding on/onto the pipelines while they are still in service, i.e. with gas flow under high pressure, such as the well-known "hot tapping". This in-service welding poses challenges for hydrogen operations. The challenge can be roughly divided into the possible austenitization of the inner pipe material exposed to hydrogen, the welding itself, which causes an increased temperature range. Both lead to a significant increase in hydrogen solubility and diffusivity compared to room temperature. In addition, possible surface reactions of the present iron oxides (e.g. magnetite or hematite) with the hot hydrogen should be considered. In this context, the knowledge of hydrogen pipelines is scarce due to the lack of operational experience. Fundamental experimental investigations are required to investigate the transferability from NG to hydrogen pipeline grids. For this reason, the present study presents a specially designed mock-up / demonstrator concept for the realistic assessment of the welding process conditions. The mock-up was designed to allow in-situ temperature measurement during the welding process as well as ex-post sample extraction for quantification of the absorbed hydrogen concentration. For safety reasons, the required volume of pressurized hydrogen was limited by inserting a solid cylinder to ensure a 1 cm thick layer of hydrogen gas. Welding experiments on the DN60 and DN200 pressurized mock-ups showed the possibility of safe welding on or onto pressurized hydrogen pipelines. Indeed, the austenitizing temperature was reached on the inner surface of the pipeline, especially on thinner-walled pipelines, using current welding parameter recommendations. This corresponded to an increased hydrogen uptake in the welded area of several ppm. From this point of view, the suggested component concept is a viable strategy for the screening of several materials and welding parameter combinations under realistic operational conditions. T2 - FEMS Euromat 2025 - 18th European Congress and Exhibition on Advanced Materials and Processes CY - Granada, Spain DA - 15.09.2025 KW - In-service welding KW - Pipeline KW - Hydrogen KW - Component test PY - 2025 AN - OPUS4-64159 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Erxleben, Kjell T1 - Component test for the assessment of in-service welding on/onto pressurized hydrogen pipelines N2 - Hydrogen is seen as the energy carrier of the future. Therefore a reliable infrastructure to transport hydrogen in a large scale is needed. A so called European hydrogen backbone out of long distance transmission pipelines is planned by European countries to create a hydrogen transport infrastructure. Due to economic reasons this will be achieved by new build pipelines such as repurposed natural Gas (NG) pipelines, converted to hydrogen useage. A general suitability for hydrogen service of low alloyed pipeline steel, as it is used for NG service today, is given. But in case of necessary in-service welding procedures in terms of e.g. hot-tapping and stoppling, the risk of a critical hydrogen uptake into the pipe materials due to much higher temeperatures while welding and the possibility of hydrogen embrittlement (HE) needs to be closely investigated. The presentation gives an overview of the current H2-SuD project, investigating the feasability of in-service welding on future hydrogen pipelines. Therefore, component-like demonstrators were developed to test (I) the additional hydrogen uptake due to in-service welding under hydrogen pressure and (II) to measure the temperature field due to different welding parameters and demonstrator geometries, especially on the inner pipe wall surface. Collected data will be used to validate a numerical simulation of the thermal field and additionally the hydrogen diffusion in the pipeline material. T2 - Presentation at The University of Manchester CY - Manchester, United Kingdom DA - 12.09.2025 KW - In-service KW - Hydrogen KW - Pipeline KW - Welding PY - 2025 AN - OPUS4-64129 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Tiebe, Carlo A1 - Bayat, Mehmet E. T1 - Measurement and Testing Methods for Sensors in Hydrogen Technologies N2 - To ensure accurate results, it is advisable to conduct sensor testing under controlled conditions, focusing on identifying specific properties and quantifying performance criteria. The necessity of these evaluations lies in determining if a potentially beneficial sensor is a good fit for a specific application. Devices are typically factory-calibrated in according to ISO/IEC 17025, followed by testing/validation prior to intended use. Subsequent inspections/validations performance tests and long-term stability should be repeated in appropriate intervals. We present the testing and calibration validation of a hydrogen sensor intended for safety applications, using dynamic dilution of hydrogen into clean, dry air. • Sensor testing for the determination of non-explosive gas mixture composition, response time and characteristic curves of gas sensors, gas measuring devices. • Hydrogen mole fraction: 100 μmol/mol to > 4.0 cmol/mol – (approximately equal to 0.1 Vol-% to > 4.0 Vol-%) • Humidity: frost-point temperatures in the range of -85 °C to 15 °C (equal to 0.2 μmol/mol to 17000 μmol/mol humidity mole fraction) at ambient pressure • Sensor output provided directly in hydrogen volume percent, as defined by the factory calibration. The results obtained from the device under test demonstrate the effectiveness of the evaluated gas sensor in detecting and quantifying hydrogen. Its responses to different amounts of hydrogen in air and reliably returns to zero. To quantify the generated hydrogen mole fractions in situ and in operando, a process-GC-TCD-TCD system calibrated against our primary gas standards was used, ensuring the highest accuracy as a designated institute for primary gas standards. This procedure provides a foundation for modern and efficient quality assurance of gas sensors. T2 - 2025 IARIA Annual Congress on Frontiers in Science, Technology, Services, and Applications CY - Venice, Italy DA - 06.07.2025 KW - Hydrogen KW - Sensor KW - Quality KW - Validation KW - Data analysis KW - Reference procedure PY - 2025 AN - OPUS4-64047 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Naster, Maximilian T1 - Experimental and numerical analyses of hydrogen flames for the thermal testing of transport packages for radioactive material N2 - In this paper we present an update of the hydrogen-based test rig for an ongoing feasibility study of using hydrogen as an energy source for the thermal testing of transport packages containing radioactive materials. The test rig is capable of combusting hydrogen for a wide range of different burner geometries, mass flows, hydrogen blends and single jet flame operations as well as a full array of burners for thermal testing can be set up. As this type of fire test according to the IAEA boundary conditions does not yet exist, a large number of preliminary investigations, safety assessments and simulations must be carried out in order to develop a viable concept for hydrogen fires. In a first step of the feasibility study, the temperature, structure, and radiative behavior of hydrogen jet flames must be surveyed. The simulation with a single hydrogen flame was investigated in a previous work. In the next step the results are used to study the interaction and structural behavior of multiple jet flames in proximity with varying nozzle distances. With the test rig completed, it will be possible in future works to design burner frames suitable for fire reference tests to make comparisons with pool and propane fires used in assessment procedure today. Thus, preliminary comparative numerical simulations are conducted to model the behavior of overlapping hydrogen jet flames using the software package Ansys®. This paper gives an overview on the current state and design of the test rig. Furthermore, the results of the simulations show that nozzle geometry, mass flow and nozzle distance provide significant design margin for designing a test fire capable of fully engulfing a specimen. T2 - PVP2025, Pressure Vessels & Piping Conference CY - Montreal, Quebec, Canada DA - 20.07.2025 KW - Computational Fluid Dynamics (CFD) KW - Hydrogen KW - IAEA fire test PY - 2025 AN - OPUS4-63865 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kröll, Mirco T1 - Harmonising Tribotests of Polymers in Hydrogen N2 - This talk harmonised methods to investigate friction and wear of commercial and experimental polymer compounds in hydrogen using several tribometers. T2 - Surface Ventures - Symposium on Hydrogen Tribology CY - Online meeting DA - 31.07.2025 KW - Hydrogen KW - Polymers KW - Tribometer KW - Wear KW - Coefficient of Friction KW - Interlaboratory comparison KW - Comparability KW - Harmonisation KW - Standardisation KW - Tribology KW - Oil-coupled compounds KW - FAIR data KW - Database KW - i-TRIBOMAT PY - 2025 AN - OPUS4-63838 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - Toward sustainable and hydrogen compatible sealing materials N2 - As sealing components, polymeric materials are used in a wide range of applications e.g. as O-rings and piston rings in high-pressure and/or cryogenic hydrogen. For these extreme demanding application, PTFE or PPS based materials are often used as high-performance polymer matrix. This project aims to provide a safe and sustainable sealing solutions for hydrogen applications. New materials with improved sustainability were investigated and compared with conventional grades. Tests were performed in hydrogen over a wide range of temperature and pressure (0.1 MPa to 40 MPa, and 100°C down to -150°C) at Kyushu University and BAM using a pin-on-disk apparatus in a continuous sliding motion. Polymer samples ran against 316L disk at 0.5 m/s and 3 MPa contact pressure. Based on the tribological results and surface analyses, promising candidates are suggested along with friction mechanisms in both high-pressure and low temperature hydrogen. T2 - STLE Meeting CY - Atlanta, Georgia, USA DA - 18.05.2025 KW - Hydrogen KW - Friction KW - Wear KW - Piston ring KW - Reciprocating seals PY - 2025 AN - OPUS4-63809 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Habib, Abdel Karim T1 - Heat radiation emanating from hydrogen and methane jet fires N2 - Modelling the heat radiation emanating from jet flames for hazard assessment purposes, is generally done using simple, steady-state approaches that give a quick result and estimation of the consequences to account for. Although nowadays computational fluid dynamics can be used to simulate this phenomenon in detail, it is still very demanding in computational power and time and generally not all required boundary conditions to achieve a reliable result are known. Therefore, even today the simpler approaches as for example the Model of Chamberlain or Johnson (mainly developed for hydrocarbon flames) are still widely used for consequence analysis. Hydrogen is becoming increasingly important as renewable energy carrier resulting in an increasing demand of “hydrogen approved” models. Since the aforenamed jet flame models were mainly developed based on data from hydrocarbon jet flame experiments, it is to be verified, that they also apply to hydrogen jet flames. To this purpose real-scale tests are carried out at the BAM Test Site Technical Safety (BAM-TTS) with the aim to assess the flame geometry and the emitted thermal radiation of hydrogen and methane jet flames. Parameters such as leakage diameter (ranging from 1 mm to 10 mm), pressure (up to max. 250 bar), release orientation (vertical or horizontal) and mass flow (up to max. 0.5 kg/s) are varied. In particular, the focus is laid on the measurement and modelling of the thermal radiation. The challenge here is the characterization of the flame geometry in an open environment and its impact on the thermal radiation. Existing heat radiation data from the literature are mostly based on unsteady outflow conditions. The experimental setup used here allows for the generation of a steady-state outflow for several minutes and thus a direct comparability with existing (steady-state) models. From these data, an assessment of the applicability of jet flame models to hydrogen jet flames is carried out not only accounting for their accuracy in predicting the heat radiation but also with regard to possible needs of further development of the models. T2 - 18th EFCE International Symposium on Loss Prevention and Safety Promotion in the Process Industries CY - Bologna, Italy DA - 08.06.2025 KW - Jet Fire KW - Hydrogen KW - Methane KW - Heat radiation PY - 2025 AN - OPUS4-63696 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kaiser, Sebastian T1 - Assessment of in service welding conditions for pressurized hydrogen pipelines via component test N2 - Hydrogen is the energy carrier of tomorrow for a fossil-free future. This requires a reliable transport infrastructure with the ability to carry large amounts of hydrogen e.g. for steel industry or chemical industry. The conversion of existing natural gas (NG) grids is an essential part of the worldwide hydrogen strategies, in addition to the construction of new pipelines. In this context, the transportation of hydrogen is fundamental different from NG as hydrogen can be absorbed into the pipeline material. Given the well-known effects of hydrogen embrittlement, the compatibility of the materials for the intended pipelines must be investigated (typically low alloy steels in a wide range of strengths and thicknesses). However, pipelines require frequent maintenance, repair or the need for installation for further outlets. In some cases, it is necessary to perform welding on or onto the pipelines while they are still in service, i.e. with active gas flow under high pressure, e.g. such as the well-known “hot tapping”. This in-service welding causes challenges for hydrogen operations in terms of additional hydrogen absorption during welding and the material compatibility. The challenge can be roughly divided into the possible austenitization of the inner pipe material exposed to hydrogen, which can lead to sufficient hydrogen absorption, and the welding itself, which causes an increased temperature range. Both lead to a significant increase in hydrogen solubility and diffusivity of the respective materials compared to room temperature. In this context, knowledge about hot tapping on hydrogen pipelines is scarce due to the lack of operating experience. Fundamental experimental investigations are required to investigate the transferability from NG to hydrogen pipeline grids. For this reason, the present study introduces a specially designed mock-up / demonstrator concept for the realistic assessment of the welding processing conditions. The mock-up was designed to enable in-situ temperature measurement during welding as well as ex-post extraction of samples for the quantification of the absorbed hydrogen concentration. For safety measures, the necessary pressurized hydrogen volume was limited by the insertion of a solid cylinder ensuring a 1 cm hydrogen gas layer. Welding experiments on the pressurized mock-ups with the diameters DN60 and DN200 have shown that the austenitization temperature can be reached on the inner surface of the pipeline, especially on thinner walled pipelines, using current welding practices. This corresponds to an increased hydrogen uptake in the welded area of several ppm. T2 - 78th IIW Annual Assembly and International Conference, IC-Session "Hydrogen Applications and Energy Transition" CY - Genoa, Italy DA - 22.06.2025 KW - Pipeline KW - Welding KW - Hydrogen KW - In-Service KW - Component-testing PY - 2025 AN - OPUS4-63638 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kaiser, Sebastian T1 - Component-like demonstrator for determination of temperature field and inner surface temperatures during in-service welding of hydrogen pipelines N2 - Hydrogen is considered as one of the most important energy carriers in the future. The necessary large-scale transport over long distances requires a suitable pipeline infrastructure. Current plannings encompass a dual-way strategy of repurposing existing natural gas (NG) pipelines, supplemented by the construction of new hydrogen pipelines. In some cases, such as necessary grid extensions or installation of bypasses in case of repair work, techniques like “hot tapping” are applied. These techniques include so-called in-service welding on pressurized pipelines and are state-of-the-art for NG grids and oil pipelines. The existing NG pipeline grid consists of a wide range of materials with different strengths, diameters, and wall thicknesses. In this context, the material compatibility is crucial. The main difference between hydrogen and NG is that hydrogen can both penetrate the material and cause hydrogen embrittlement. In that connection, in-service welding encompasses elevated temperatures for a certain time during the typically multi-layer welding process. Locally even austenitization temperature can be reached or surpassed. Austenite has a higher hydrogen solubility at a significantly lower diffusion rate, which could lead to a critical hydrogen accumulation. Especially the inner pipe surface temperature is from utmost interest, as this interface is exposed to the pressurized hydrogen (up to 100 bar). However, direct measurement of the locally occurring temperatures is very challenging. For this reason, a component-like geometry was developed. The geometry consists of a pipeline segment with a metal sheet joined to the pipe segment, representing similar heat dissipation conditions as in the field. In addition, typical welding parameters were applied that are currently used in the NG grid. This allows the welding of realistic multi-layer fillet welds on the outer pipe wall with simultaneous temperature measurement using manifold thermocouples at defined positions: (1) adjacent to the weld seam on the outer pipe surface, (2) on the inner pipe surface and (3) on the welded metal sheet. To ensure realistic conditions, manual shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW) was investigated. The effects of different wall thicknesses and welding heat inputs on the temperature distribution and peak temperatures achieved on the inner pipe surface during welding vary depending on the chosen method. Peak temperatures above austenitization temperature up to 1078 °C have been measured on L245 pipes with wall thickness of 3.6 mm. For pipes made from higher strength materials, such as L485, with a wall thickness of 8 mm, peak temperatures between 607 °C and 755 °C were recorded. Temperature and austenitization directly affects hydrogen diffusivity and solubility, showing the importance of the findings. The temperature profile and cooling conditions influence the mechanical properties of the material as well. For this reason, metallurgical investigations are carried out to assess the hardness and microstructure of the welds. Hardening up to 248 HV10 was detected in the heat-affected zone (HAZ) of the top layer, which could lead to a locally increased susceptibility to hydrogen assisted cracking. Meanwhile, the minimum hardness found in the HAZ of the root layer was as low as 144 HV10, indicating a softening. The results of this study provide valuable insights into the suitability of existing materials and geometries for hydrogen transport. Secondly, the data collected will serve as a basis for planned numerical simulations to further improve knowledge and optimize welding processes to ensure the integrity and safety of hydrogen pipelines. T2 - 78th IIW Annual Assembly and International Conference, Meeting of Commission II-C: "Testing and Measurement of Welds" CY - Genoa, Italy DA - 22.06.2025 KW - Pipeline KW - Welding KW - Inner-surface temperature KW - Temperature measurement KW - Hydrogen PY - 2025 AN - OPUS4-63637 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Koerdt, Andrea T1 - Hydrogen storage & Microbiologically influenced corrosion - Improved test system for Stability and Durability of the Materials & Gas N2 - Underground hydrogen storage (UHS) is a strategic step towards implementing the hydrogen economy. Achieving the required infrastructure by 2050 necessitates advancements in hydrogen-dedicated assets and the evaluation of existing infrastructure. The unique conditions in UHS require an experimental set-up to simulate UHS operating conditions, which allows to assess the readiness of current storage and transmission for hydrogen, and develop new technologies for material-resistance, operational-simulations, and risk-assessments. In addition to the physical/chemical conditions in UHS (e.g., salinity, hydrogen concentration, operating temperature/-pressure, water content), biological threats must also be considered. Therefore, we present here a high-pressure-set-up, developed for research/-industrial testing purposes. Currently, UHS-experiments for microbiologically-influenced-corrosion (MIC) are performed in standard autoclaves with relatively high volumes/pressures; they were primarily designed for material-specific investigations. While these methods provided some useful information for biological questions, they had significant limitations. Besides, the rapid depressurization that occurs with standard autoclaves can greatly affect materials, especially amorphous materials like polymers, causing damage that isn't due to the actual hydrogen storage. This presents a challenge, as the test results may not accurately reflect real-world conditions. To address these issues, specialized autoclaves have been developed to allow for slower depressurization while also enabling continuous monitoring of gases and liquids during the experiment. Such modifications could help obtain more accurate and reliable data. The novel UHS-simulation-set-up presented here is designed with a controlled independently temperature and pressure. Field samples can be used to mimic geology, water chemistry, construction materials, and microbiological conditions. Most significant advantages of the set-up are: 1. It allows for liquid addition during the test, enabling the study of biocides or the evaluation of operating setups. 2. It permits liquid/-gas sampling during the test, allowing for more efficient monitoring of testing conditions and a better understanding of the process over time. Additionally, a low-release function is added, which is particularly important for studying MIC to avoid negative side effects, on the material (e.g. polymers/corrosion product-layer/cells itself) which might occur due to the fast pressure release. T2 - MATHEA | MATerials in Hydrogen related Energy Applications 2025 CY - Hamburg, Germany DA - 24.06.2025 KW - MIC KW - MISTRAL KW - Underground storage KW - Hydrogen KW - Polymer KW - Metal PY - 2025 AN - OPUS4-63567 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Characterization of hydrogen trapping in a CoCrFeMnNi high-entropy alloy charged up to 1000 bar high-pressure hydrogen N2 - First studies on the mechanical behavior of high-entropy alloys (HEAs) in high-pressure hydrogen environment are available. In contrast, the underlying hydrogen absorption, diffusion and trapping in these HEAs like the Cantor-alloy was less in the scientific scope so far. For that reason, the CoCrFeMnNi-HEA was compared to a conventional AISI 316L austenitic steel, by exposing to high-pressure hydrogen charging at 200 bar and very-high pressure at 1,000 bar. Thermal desorption analysis (TDA) was applied with different heating rates (0.125 K/s to 0.500 K/s), see Fig. 1a to d. The underlying TDA spectra were analyzed in terms of a reasonable peak deconvolution to into a defined number of peaks and the calculation of the activation energies for the respective and predominant hydrogen trap sites. Both materials show a comparable hydrogen diffusivity. The obtained activation energies suggest that in case of the CoCrFeMnNi-HEAs an interaction of the austenitic phase as well as the direct atomic bonding of hydrogen to the metal atoms are the dominant traps, since “impurities” such as carbides or inclusions are only present in trace amounts. Available literature suggests that the Cr and Mn-content is here of special interest for the direct hydrogen bonding at solute atoms. In addition, the trap occupancy rate must be considered in terms of a pressure-related hydrogen absorption. The derived apparent hydrogen solubility was in the order: 316L < CoCrFeMnNi-HEA for both charging pressures. Especially, the 1,000 bar values lead to noteworthy results with > 70 wt.ppm for the AISI 316L and >130 wt.ppm for the CoCrFeMnNi. In fact, both the hydrogen diffusion and trapping data on gaseous high-pressure hydrogen charged HEAs are rare so far. The results of the present study allow a deeper understanding of hydrogen trapping in the regarded CoCrFeMnNi-system. T2 - 78th IIW Annual Assembly and International Conference CY - Genoa, Italy DA - 26.06.2025 KW - Hydrogen KW - Thermal desorption analysis KW - High-pressure charging KW - Trapping KW - Diffusion PY - 2025 AN - OPUS4-63542 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bernardy, Christopher T1 - Experimental investigation of large scale hydrogen diffusion jet flames N2 - Hydrogen is a promising alternative to natural gas in industrial energy applications which would serve the goal of limiting global warming. However, wide application of hydrogen requires specific safety considerations taking into account that hydrogen is stored and transported under much higher pressure than natural gas. Thus, one scenario to be considered for hazard assessment is a sudden release of hydrogen from a leakage or safety valve and its subsequent ignition. For hydrocarbon flames, various jet flame models are available. However, hydrogen flames significantly differ from hydrocarbon flames in their combustion behavior, so that the applicability of these models to hydrogen has to be investigated. For that purpose, reals scale tests were carried out at the BAM Test Site Technical Safety. In addition, hydrocarbon jet flames (methane) were investigated. In these tests, the flame geometry and the thermal heat radiation were investigated for a release angle of 90°, for different release pressures (up to 220 bar) and mass flows (up to 0.175 kg/s). While existing heat radiation data from the literature are mostly based on unsteady outflow conditions and/or releases in still air, the experiments presented here are focused on ensuring a constant mass flow over the release duration under realistic free field conditions (with wind influence). This allows a better comparability with the stationary jet flame models and assessment of wind influence on model predictions. A number of parameters such as the surface emissive power of the jet flame and the radiant heat fraction were determined. A detailed comparison of the obtained experimental results with literature radiation models was performed. Good agreement between experimental and literature data was found for hydrogen whereas significant differences were identified for methane. Based on the investigations, empirical equations for modelling jet flames could be derived. T2 - American Society of Mechanical Engineers - Turbomachinery Technical Conference & Exposition CY - Memphis, TN, USA DA - 15.06.2025 KW - Hydrogen KW - Release KW - Thermal radiation KW - Diffusion jet flame PY - 2025 AN - OPUS4-63454 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Grimault de Freitas, Tomás T1 - Repair Welding on Future Pressurized Hydrogen Pipelines N2 - Hydrogen is the energy carrier for a sustainable future without fossil fuels. This requires a reliable transport infrastructure. In this context, the conversion of existing natural gas (NG) grids is an essential part of the worldwide hydrogen strategies, in addition to the construction of new pipelines. Given the known effects of hydrogen embrittlement, the compatibility of the materials already in use (typically low alloy steels in a wide range of strengths and thicknesses) must be investigated. Initial comprehensive studies of the hydrogen compatibility of pipeline materials indicate that these materials can be used to a certain extent. However, pipelines require frequent maintenance and repair. In some cases, it is necessary to perform welding on pipelines while they are under pressure, such as the well-known tapping of natural gas grids. This in-service welding presents additional challenges for hydrogen operations in terms of additional hydrogen absorption during welding and material compatibility. The challenge can be roughly divided into the possible austenitization of the inner pipe material exposed to hydrogen, which can lead to sufficient hydro- gen absorption, and the welding itself, which causes an increased temperature range. Both lead to a significant increase in hydrogen solubility and diffusivity of the respective materials compared to room temperature. In this context, knowledge about hot tapping on hydrogen pipelines is scarce due to the lack of operating experience. Fundamental experimental investigations are required to investigate the possibility of transferring the state-of-the-art concepts from natural gas to hydrogen pipeline grids to ensure that no critical material degradation occurs due to the potentially increased hydrogen uptake. For this reason, the presentation will present the state of the art in hydrogen pipeline hot tapping, including current research projects and their solution strategies in terms of pressurized mock-ups and basic testing scenarios. T2 - ASTM Conference on Hydrogen Materials CY - La Rochelle, France DA - 03.06.2025 KW - Component Test KW - Hydrogen KW - In-service welding KW - Pipeline PY - 2025 AN - OPUS4-63332 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Grimault de Freitas, Tomás T1 - Hollow Specimen Technique for Tests in High-Pressure Hydrogen Gas: The Path Towards Standardisation and the Case Study of a Pipeline Steel and its Weld N2 - The hollow specimen technique is a simple method that has the potential to make material qualification with gaseous pressurized hydrogen widely applicable for the hydrogen industry at low cost. The feasibility of this method has been demonstrated in several studies, leading to the establishment of an ISO committee for its standardization. Questions have emerged during this process, that currently prevent the method from being standardized for hydrogen testing. These questions relate to specimen geometry, specimen manufacturing and gas quality and are being systematically addressed in the TransHyDE-H2HohlZug project. The aim is to close the identified gaps towards the standardization of this method for hydrogen testing. This contribution presents the structure and milestones of the project, followed by the results regarding the influence of specimen production and its response to hydrogen effects. Depending on the production method, different roughness and residual stresses can be expected on the inner hole surface of the specimens. This is of importance since an increase in stress concentration sites have been found to be associated to a higher severity of hydrogen effects. This influence has been investigated after applying the following machining processes: a) drilled only; b) drilled and reamed; c) drilled and honed; d) electro-discharge machining (EDM) and honed; e) EDM and reamed. Roughness measurements using a profilometer, electron back-scatter diffraction (EBSD) analysis and microhardness tests have been performed previous to mechanical testing to infer on the effect of the different production methods on the surface of the inner hole. Next, the specimens were mechanically tested via slow strain rate tensile tests in a argon and in hydrogen, both at 150 bar and room temperature. Here, a strain-rate sensibility analysis was also performed to identify an optimal strain-rate for the mechanical tests. Based on the results an optimal production method is identified and proposed. T2 - ASTM Conference on Hydrogen Materials CY - La Rochelle, France DA - 03.06.2025 KW - Hydrogen KW - Hydrogen Embrittlement KW - Hollow Specimen Technique KW - High-Pressure Gaseous Hydrogen KW - Austenitic Stainless Steel KW - H2HohlZug KW - TransHyDE KW - Tensile Test KW - Pipeline Steel PY - 2025 AN - OPUS4-63329 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Tiebe, Carlo T1 - Error prevention, damage prevention, and safety management in hydrogen technologies N2 - This tutorial presents requirements and properties of sensor systems and shows application examples of these technologies for safety and process control for hydrogen technologies. Sensor systems are widely used in hydrogen technologies. The focus is on gas sensors as well as sensors for pressure, temperature, and gas flow. These systems are applied, among other things, for monitoring and control of operating conditions, indication of hazardous conditions and triggering of alarms. To integrate the error avoidance and loss prevention strategy into hydrogen technologies. This includes the implementation of preventive measures as elements of safety management to identify and eliminate potential sources of error. In addition, training should be specifically focused on avoiding errors and the safe use of hydrogen technologies. A well-thought-out strategy for error prevention makes a significant contribution to preventing accidents and increasing overall safety when using hydrogen. T2 - Sensor and Measurement Science International (SMSI) CY - Nuremberg, Germany DA - 06.05.2025 KW - Hydrogen KW - Safety Management KW - Gas Sensors KW - Performance Testing PY - 2025 AN - OPUS4-63280 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Erxleben, Kjell T1 - Component test concept for evaluation of in-service welding on pressurized hydrogen pipelines N2 - Hydrogen is set as the energy carrier of tomorrow and most countries will achieve large-scale hydrogen transport through the conversion of the natural gas (NG) grid and the construction of new pipelines. The interaction between hydrogen and the pipeline materials differs fundamentally from that of NG, as hydrogen is readily absorbed into the material. Considering the possible hydrogen embrittlement (HE), the compatibility of the pipeline materials (low-alloyed steels with a wide strength/thickness range) must be investigated. However, pipelines require intervention for maintenance, repair, or grid expansion with welding on/onto the pipelines while in service, i.e. the well-known "hot tapping" and "plugging" or “stoppling”. The challenges compared to NG can be broadly divided into the possible austenitization of the inner pipe material exposed to hydrogen and the welding itself. Both result in a significant increase in hydrogen solubility and could potentially pose challenges in terms of HE. Emphasis is placed on the word "could" because knowledge of "hot tapping" on hydrogen pipelines is scarce due a lack of service experience. To this end, this study proposes a concept for a component-like demonstrator with the objectives: (1) safe feasibility of "hot tapping" on pressurized model hydrogen pipeline sections, (2) facilitate ex-post sample extraction for the purpose of quantifying the absorbed hydrogen concentrations, and (3) ensure in-situ temperature measurement during welding to monitor the pipeline surface temperature. For safety reasons in the event of an unintentional "burn-through", a solid cylinder was inserted in the demonstrator to restrict the hydrogen gas volume to a small, pressurized layer. Reference pipeline surface temperature measurements were ensured on comparable, unpressurized geometries. The investigated range of welding conditions was investigated for representative material/thickness combinations (DN50 to DN200), suggesting the feasibility of the demonstrator for the determination of reliable in-service welding conditions for both installed and new pipelines for hydrogen service. T2 - 20th Pipeline Technology Conference ptc2025 CY - Berlin, Germany DA - 06.05.2025 KW - In-service KW - Hydrogen KW - Pipeline KW - Repair welding KW - Component test PY - 2025 AN - OPUS4-63170 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Erxleben, Kjell T1 - Quantification of hydrogen uptake during in-service hydrogen pipeline welding N2 - Hydrogen must be transported on a large scale from producers to consumers to ensure the energy transition. The necessary pipeline grid is achieved by conversion of the natural gas (NG) grid and building new pipelines. Welding during service as part e.g. of “hot-tapping” is unavoidable for maintenance/repair/expansion. Based on existing studies, the basic material compatibility of (low-alloyed) pipeline steels with hydrogen is postulated. However, this cannot be assumed for the case of in-service welding on pipelines in pressurized condition. The reason is the increased temperature e.g. by preheating and (in particular) during welding of the single passes. As a result, the inner pipeline surface undergoes multiple short-term heating but to high temperatures. In particular, the first passes can result in a temperature close to the austenitic transformation of the material for small wall thicknesses. Both increase the hydrogen uptake into the welded joint. If hydrogen embrittlement is likely to occur, depends on the hydrogen uptake, which must be quantified. For this purpose, welding experiments on pressurized demonstrators were conducted. The hydrogen uptake at 100 bar was compared to reference experiments with nitrogen. A new sample extraction routine for the quantification of the weld-zone specific hydrogen uptake was established. Comprehensive experiments with different steels (P235, L360, L485), wall thicknesses (4.1 mm to 7.8 mm) and diameters (DN50 and DN200) were conducted. In addition, the influence of the welding layer sequence on the hydrogen uptake between single- and multi-layer welds was investigated. Analytical approaches were used to approximate the hydrogen uptake in the respective weld zones. The main findings were that the layer sequence and especially the wall thickness have a large influence on the hydrogen uptake. T2 - 20th Pipeline Technology Conference ptc2025 CY - Berlin, Germany DA - 06.05.2025 KW - In-service KW - Hydrogen KW - Pipeline KW - Repair welding KW - Component test PY - 2025 AN - OPUS4-63165 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Nguyen, Ngoc Tam Thi T1 - Reinventing Piping for Hydrogen Applications – A Composite Approach N2 - A key step towards achieving climate neutrality in the European Union (EU) by 2050 is the transition to renewable energy sources. Green hydrogen plays a central role in this shift but remains costly, particularly through the utilization of PEM electrolysis. Currently, around 50% of the costs associated with electrolyser systems are attributed to system peripherals, underscoring the potential for cost savings through standardization and the use of cost-effective materials [Tja17, IRE20]. In the collaborative project "PolyH2Pipe", the Institute of Plastics Processing in Industry and Craft (IKV), the Welding and Joining Institute (ISF) and BAM Division 5.3 are developing media-carrying pipe systems made of continuous fiber-reinforced thermoplastics (TP-FR) for hydrogen applications. The project aims to design these pipes, develop suitable joining techniques and validate the requirements for these piping systems. This research initiative serves as a foundational basis for the subsequent market introduction of large-scale TP-FR pipe systems for electrolysers and fuel cell systems. Initial test results will be presented as a part of the talk during the colloquium. T2 - H2Safety Colloquium - Materials compatibility and properties CY - Online meeting DA - 14.05.2025 KW - Hydrogen KW - Polymer Matrix Composites KW - Electrolyser KW - Piping PY - 2025 AN - OPUS4-63134 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kröll, Mirco T1 - Harmonized tribological testing of polymers in hydrogen N2 - To investigate typical polymer compounds and a potential alternative to be used in hydrogen compressors, tribological tests have been performed with several tribometers in hydrogen atmosphere. The compounds used were a commercially available PEEK matrix with 10 wt-% PTFE, graphite, and short carbon fibers each (supplied by company Polytron), a PPS matrix with 10 wt-% PTFE and graphite (supplied by company MOCOM) and an experimental PA12 matrix with PTFE, chemically coupled with an oleyl alcohol, as additive (supplied by the polymer research institute IPF). For all compounds a steel counter disc (type 316L / 1.4404) with a lapped surface was used in a cylinder on disc setup. The focus of this work is to study the tribological performance of the polymers in hydrogen atmosphere. Additionally, tests were carried out with up to three different tribometers at two institutions. The challenge to compare and harmonize equipment, procedures, and methods is an important part of the study. This naturally includes the determination of the wear volumes of the polymeric cylinders. Furthermore, selected results of the wear and the resulting change in the contact geometry were compared by FEM simulations and an analytical model. T2 - Colloquium H2Safety@BAM, Materials properties and compatibility CY - Online meeting DA - 14.05.2025 KW - Hydrogen KW - Polymers KW - Tribometer KW - Wear KW - Coefficient of Friction KW - Interlaboratory comparison KW - Comparability KW - Harmonisation KW - Standardisation KW - Tribology KW - Oil-coupled compounds PY - 2025 AN - OPUS4-63103 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Karapanagiotis, Christos T1 - Toward a Digital Twin of Hydrogen Pressure Vessels Enabled by Distributed Fiber Optic Sensors N2 - We present a digital replica of a hydrogen pressure vessel enabled by distributed fiber optic sensors (DFOS). This digital replica dynamically displays and updates the vessel’s structural condition by calculating strain residuals defined as the difference between the measured DFOS strain and the expected strain based on pressure data. As an example, we show the ability of the DFOS to detect and localize damage caused by drilling six holes into the vessel’s body. This digital replica represents a foundational step toward a fully integrated digital twin for predictive maintenance and remaining lifetime prognosis. T2 - Sensor and Measurement Science International 2025 CY - Nuremberg, Germany DA - 06.05.2025 KW - Fiber optic sensors KW - Hydrogen KW - Digital twins KW - Structural health monitoring KW - Machine learning KW - Predictive maintenance PY - 2025 AN - OPUS4-63087 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kaiser, Sebastian T1 - Evaluation of welding on in-service pressurized hydrogen pipelines by component testing N2 - Hydrogen transportation is fundamentally different from natural gas (NG) as it can be absorbed into the pipeline material. However, pipelines require frequent maintenance or repair, in some cases on or onto the pipelines while they are still under pressure. This in-service welding causes challenges for hydrogen operations. They can be roughly divided into: (1) possible austenitization of the inner pipe material exposed to hydrogen, and (2) welding itself with its temperature cycles. Both lead to a significant increase in hydrogen solubility/diffusivity of the materials. Fundamental investigations are required due to the missing service experience. The present study introduces a specially designed demonstrator concept for the assessment of the welding processing conditions. The mock-up was designed to enable temperature measurement during welding as well as ex-post extraction of samples for the quantification of the absorbed hydrogen. The necessary pressurized hydrogen volume was limited by the insertion of a solid cylinder. Welding experiments on the pressurized mock-ups (DN50 and DN200) have shown that the austenitization temperature is nearly reached on the inner surface of the pipeline. This corresponds to a significant hydrogen absorption of several ppm in the welded joint, especially for thin-walled pipelines. Nonetheless, a potential hydrogen assisted cracking was not identified. T2 - 24. Werkstofftechnisches Kolloquium CY - Chemnitz, Germany DA - 02.04.2025 KW - Pipeline KW - In-Service KW - Welding KW - Hydrogen PY - 2025 AN - OPUS4-62917 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Erxleben, Kjell T1 - Component test for safety assessment of in-service welding on / onto pressurized hydrogen pipelines N2 - Hydrogen is the energy carrier of tomorrow for a fossil-free future. This requires a reliable transport infrastructure capable of transporting large quantities of hydrogen, e.g. for the steel and chemical industries. In addition to the construction of new pipelines, the conversion of existing natural gas (NG) networks is an essential part of global hydrogen strategies. The transport of hydrogen is fundamentally different from that of NG, as hydrogen can be absorbed into the pipeline material. Given the known effects of hydrogen embrittlement, the compatibility of the materials for the proposed pipelines (typically low alloy steels in a wide range of strengths and thicknesses) must be investigated. However, pipelines require frequent maintenance, repair, or the need to install additional outlets. In some cases, it is necessary to perform welding on or to the pipelines while they are still in service, i.e. with active gas flow under high pressure, such as the well-known "hot tapping". This in-service welding poses challenges for hydrogen operations in terms of additional hydrogen absorption during welding and material compatibility. The challenge can be roughly divided into the possible austenitization of the inner pipe material exposed to hydrogen, which can lead to sufficient hydrogen absorption, and the welding itself, which causes an increased temperature range. Both lead to a significant increase in hydrogen solubility and diffusivity of the respective materials compared to room temperature. In this context, knowledge about hot tapping on hydrogen pipelines is scarce due to the lack of operational experience. Fundamental experimental investigations are required to investigate the transferability from natural gas to hydrogen pipeline networks. For this reason, the present study presents a specially designed mock-up / demonstrator concept for the realistic assessment of the welding process conditions. T2 - Materials Week 2025 CY - Frankfurt am Main, Germany DA - 02.04.2025 KW - In-service KW - Hydrogen KW - Pipeline KW - Repair welding PY - 2025 AN - OPUS4-62874 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Erxleben, Kjell T1 - Component test to simulate critical conditions of hydrogen assisted cracking in submerged arc welded offshore steel N2 - Offshore Wind Turbines (OWT) are a key factor in tomorrow's sustainable energy generation. The ever� increasing installation depth and weight of OWTs require suitable foundation concepts such as monopiles or tripods. Typically, mild steels such as S420ML are used with plate thicknesses of up to several hundred mm, resulting in high restraints in the welded joints. The large plate thickness requires high-efficiency welding processes such as submerged arc welding (SAW) with multiple wires. Due to the very high stiffness and plate thickness of the large-scale offshore structure, a susceptibility to time� delayed hydrogen assisted cracking (HAC) may occur. For this reason, a minimum waiting time (MWT) of up to 48 h must be considered before NDT is conducted. The evaluation of the crack susceptibility is complex due to the component size and stiffness of real offshore structures. For this purpose, a near-component test geometry has been developed to transfer the real stiffness conditions to laboratory (i.e. workshop) scale. The 350 kg mock-up consisted of heavy plates (thickness 50 mm, seam length 1,000 m) joined by a 22-pass submerged-arc weld. Additional stiffeners simulated the effect of high restraint or shrinkage restraint of the weld. Extreme scenarios of hydrogen absorption during welding were simulated by using flux in dry (HD < 5 ml/100g Fe) and wet (HD > 15 ml/100g Fe) conditions. Weld residual stresses were determined using a robotic X-ray diffractometer. Areas of critical tensile residual stress (at the yield strength level) were found in the weld metal and in the heat affected zone, suggesting that these weld subzones are the most critical in the case of hydrogen ingress. To identify possible delayed cracking, the welds were inspected by phased array ultrasonic testing (PAUT) after welding, 6 h, 12 h, 24 h, and a maximum of 48 h. Summarized, no significant occurrence of HAC was detected, indicating the high crack resistance of the welded joint, i.e., a suitable combination of base material, welding consumable and parameters. T2 - Materials Week/Steel Innovation CY - Frankfurt am Main, Germany DA - 02.04.2025 KW - Cold cracking KW - Component test KW - Hydrogen KW - Minimum waiting time KW - Offshore steel grade PY - 2025 AN - OPUS4-62873 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Nietzke, Jonathan T1 - H2HohlZug: Standardisation of a New, Cost-effective Method for Material Characterisation for the Hydrogen Economy N2 - The feasibility of the method for slow strain tensile tests has been demonstrated in several studies, leading to the establishment of the ISO/TC 164/SC 1/WG 9 ISO committee for its standardisation. Questions have emerged during this process, that currently prevent the method from being standardised for hydrogen testing. These questions relate to specimen geometry, specimen manufacturing and gas quality and are being systematically addressed in the TransHyDE-H2HohlZug project. T2 - TrasnsHyDE Abschlusskonferenz CY - Berlin, Germany DA - 25.03.2025 KW - Hydrogen KW - Hydrogen Embrittlement KW - High-Pressure Gaseous Gas KW - Hollow Specimen Technique KW - TransHyDE KW - H2HohlZug PY - 2025 AN - OPUS4-62823 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bernardy, Christopher T1 - Large scale safety investigations of hydrogen jet flames N2 - For industrial applications dealing with hydrogen, the definition of safety distances and the assessment of possible hazards emanating from releases is mandatory. Since hydrogen is usually stored and transported under pressure, one scenario to be considered is the momentum driven release of hydrogen from a leakage with subsequent ignition. In this scenario, the emitted heat radiation from the resulting jet flame to the surroundings has to be determined to define adequate safety distances. For hydrocarbon flames, different jet flame models are available to assess the hazards resulting from an ignited jet release. Since hydrogen flames differ from hydrocarbon flames in their combustion behavior, it has to be checked if these models are also applicable for hydrogen. To evaluate the accuracy of these models for hydrogen jet flames, tests with a horizontal outlet at large-scale are carried out at the BAM Test Site for Technical Safety (BAM-TTS). Herein, the flame geometry and the heat radiation at defined locations in the surroundings are recorded for varying release parameters such as release pressure (currently up to max. 250 bar), mass flow (up to max. 0.175 kg/s) at an outlet diameter of 30 mm. The challenge here is the characterization of the flame geometry in an open environment and its impact on the thermal radiation. Existing heat radiation data from the literature are mostly based on unsteady outflow conditions. For a better comparability with the steady state jet flame models, the experiments presented here are focused on ensuring a constant mass flow over the release duration (currently 120 s) to obtain a stationary jet flame. In addition, stationary outflow tests with hydrocarbons (methane) were also carried out, which are intended to serve as reference tests for checking flame models based on hydrocarbon data. The comparison of the flame geometry shows that hydrogen jet flames with the same outlet mass flow have a greater flame length (average deviation of 15 %) but a smaller flame diameter than methane jet flames (average deviation of 17 %). Conclusions regarding thermal radiation show that the proportion of total combustion energy emitted as thermal radiation is lower for hydrogen (xrad = 0.04–0.08) than for methane (xrad = 0.05–0.1). A comparison of the surface emissive power (SEP) of the jet flame shows a SEP range of 7 kW/m²-15 kW/m² for hydrogen and 3 kW/m² - 9,5 kW/m² for methane. T2 - H2 Safety - Colloquium - Process and Plant Safety CY - Online meeting DA - 19.02.2025 KW - Hydrogen KW - Release KW - Radiant heat fraction KW - Jet flame KW - Thermal radiation PY - 2025 AN - OPUS4-62779 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hickel, Tilmann T1 - Effect of Hydrogen on the Phase Stability of Steels N2 - In this work, we studied the role of extreme hydrogen concentrations on the relative stability of the fcc/bcc/hcp phases using the ab initio thermodynamics. The results indicate that at low hydrogen chemical potentials the stability of the fcc phase, which can be representative of retained austenite (RA) in steels, is slightly enhanced by the presence of H atoms. In contrast, at high hydrogen chemical potentials the bcc phase is stabilized by H. Moreover, since the excess volume of the hydrogen-rich bcc phase is significantly larger than that of the fcc phase, the presence of a stress field can change the relative stability of these phases in the coexistence regions of the phase diagram. This feature is particularly important for cyclic loading conditions: during loading cycles forward and reverse phase transformations occur and the H released by these transformations can damage the material. T2 - TMS Annual Meeting 2024 CY - Orlando, FL, USA DA - 03.03.2024 KW - Hydrogen KW - Ab initio thermodynamics KW - Multiscale simulation KW - Hydride formation KW - Workflow PY - 2024 AN - OPUS4-62730 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hickel, Tilmann T1 - Fundamental insights into the mechanism of hydrogen embrittlement N2 - The talks starts with a study on H trapping and embrittlement in high-strength Al alloys. Then the phase stability and transformation between different Fe-H phases is discussed, together with implications on crack nucleation. In the last part MD-MC simulation of hydride formation at crack tips in Al alloys are shown. T2 - Integrated Computational Materials, Process and Product Engineering Conference, IC-MPPE CY - Leoben, Austria DA - 06.06.2024 KW - Hydrogen KW - Ab initio thermodynamics KW - Multiscale simulation KW - Hydride formation KW - Cracks PY - 2024 AN - OPUS4-62727 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hickel, Tilmann T1 - Hydrogen redistribution during electrochemical charging and mechanical testing: insights from a combined ab initio and finite element method N2 - In advanced high strength steels the mechanisms of hydrogen embrittlement are expected to be strongly connected to the amount of retained austenite (RA) contained in the microstructure and its transformation upon deformation. We have developed a multi-scale model for the hydrogen redistribution during hydrogen charging and tensile loading within martensitic/austenitic microstructure. Ab initio simulations have been used to resolve the complex energy profile of hydrogen in the martensite/austenite interface. Representative microstructures with different amounts of RA have been converted form experimental SEM-EBSD measurements. Simulations with the finite element method (FEM) have been used to analyse H concentration profiles within the microstructure. The simulations confirm an accumulation of H within the austenitic phase during charging, which undergoes a phase transformation under applied mechanical load during tensile testing and releases accumulated H into the martensite matrix. As a result, there is a pronounced H segregation to the microstructure regions subjected to high hydrostatic tensile stresses and plastic strains, which has a strong impact on the embrittlement behaviour. T2 - DPG Frühjahrstagung Sektion SKM CY - Berlin, Germany DA - 17.03.2024 KW - Hydrogen KW - Steel KW - Structural transformation KW - Ab initio simulation KW - Multiscale simulation PY - 2024 AN - OPUS4-62726 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Hickel, Tilmann T1 - Data driven research on hydrogen in metals N2 - The talk gives an overview on data-driven research on hydrogen in metals performed at BAM. The focus is on a ab-initio based high-throughput study on the hydrogen solubility in metals and metallic alloys. Furthermore, the redistribution of hydrogen in transforming microstructures is addressed. The talk ends with an explanation of participant projects in NFDI-MatWerk, motivating the formation of a new project connected to hydrogen technology. T2 - DGM Fachausschuss “Wasserstoffeffekte in Werkstoffen" CY - Saarbrücken, Germany DA - 05.05.2024 KW - Hydrogen KW - Solubility KW - High-throughput study KW - Ab initio simulation KW - NFDI-MatWerk PY - 2024 AN - OPUS4-62721 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Determination of inner pipe surface temperatures during in-service welding on hydrogen pipelines by means of component-like mock up experiments N2 - Hydrogen is considered as one of the most important energy carriers in the future. The necessary large-scale transport over long distances requires a suitable pipeline infrastructure. Current plannings encompass a dual-way strategy of repurposing existing natural gas (NG) pipelines, supplemented by the construction of new hydrogen pipelines. In some cases, such as necessary grid extensions or installation of bypasses in case of repair work, techniques like “hot tapping” are applied. These techniques include so-called in-service welding on pressurized pipelines and are state-of-the-art for NG grids and oil pipelines. The existing NG pipeline grid consists of a wide range of materials with different strengths, diameters, and wall thicknesses. In this context, the material compatibility is crucial. The main difference between hydrogen and NG is that hydrogen can both penetrate the material and cause hydrogen embrittlement. In that connection, in-service welding encompasses elevated temperatures for a certain time during the typically multi-layer welding process. Locally even austenitization temperature can be reached or surpassed. Austenite has a higher hydrogen solubility at a significantly lower diffusion rate, which could lead to a critical hydrogen accumulation. Especially the inner pipe surface temperature is from utmost interest, as this interface is exposed to the pressurized hydrogen (up to 100 bar). However, direct measurement of the locally occurring temperatures is very challenging. For this reason, a component-like geometry was developed. The geometry consists of a pipeline segment with a metal sheet joined to the pipe segment, representing similar heat dissipation conditions as in the field. In addition, typical welding parameters were applied that are currently used in the NG grid. This allows the welding of realistic multi-layer fillet welds on the outer pipe wall with simultaneous temperature measurement using manifold thermocouples at defined positions: (1) adjacent to the weld seam on the outer pipe surface, (2) on the inner pipe surface and (3) on the welded metal sheet. To ensure realistic conditions, manual shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW) was investigated. The effects of different wall thicknesses and welding heat inputs on the temperature distribution and peak temperatures achieved on the inner pipe surface during welding vary depending on the chosen method. Peak temperatures above austenitization temperature up to 1078 °C have been measured on L245 pipes with wall thickness of 3.6 mm. For pipes made from higher strength materials, such as L485, with a wall thickness of 8 mm, peak temperatures between 607 °C and 755 °C were recorded. Temperature and austenitization directly affects hydrogen diffusivity and solubility, showing the importance of the findings. The temperature profile and cooling conditions influence the mechanical properties of the material as well. For this reason, metallurgical investigations are carried out to assess the hardness and microstructure of the welds. Hardening up to 248 HV10 was detected in the heat-affected zone (HAZ) of the top layer, which could lead to a locally increased susceptibility to hydrogen assisted cracking. Meanwhile, the minimum hardness found in the HAZ of the root layer was as low as 144 HV10, indicating a softening. The results of this study provide valuable insights into the suitability of existing materials and geometries for hydrogen transport. Secondly, the data collected will serve as a basis for planned numerical simulations to further improve knowledge and optimize welding processes to ensure the integrity and safety of hydrogen pipelines. T2 - IIW Intermediate Meeting, Com. II-A CY - Trollhättan, Sweden DA - 10.03.2025 KW - Testing KW - In-service welding KW - Hydrogen KW - Pipelines PY - 2025 AN - OPUS4-62690 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Tiebe, Carlo T1 - Error Prevention, Damage Prevention, and Safety Management in Hydrogen Technologies N2 - In order to integrate the error prevention and damage prevention strategy into hydrogen technologies, it is important to proactively look out for potential weaknesses in the systems and processes. This includes the implementation of preventive measures as elements of safety management in order to identify and eliminate potential sources of error. In addition, training should be specifically focussed on avoiding errors and the safe use of hydrogen technologies. The principial approach of a gas sensor testing laboratory shows how to ensure reliable results, it is advisable to conduct sensor testing under controlled conditions, focusing on identifying specific properties and quantifying performance criteria. A well thought-out strategy for error prevention makes a significant contribution to preventing accidents and increasing overall safety when using hydrogen. T2 - 5th Germany-Korea Hydrogen Conference CY - Halle (Saale), Germany DA - 22.10.2024 KW - Hydrogen KW - Safety KW - Safety Management KW - Error Prevention KW - Reference Procedure PY - 2024 AN - OPUS4-62563 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Assessment of in-service welding conditions for pressurized hydrogen pipelines via component test N2 - Hydrogen is the energy carrier of tomorrow. This requires a reliable transport infrastructure with the ability to carry large amounts of hydrogen e.g. for steel industry or chemical industry. The conversion of existing natural gas (NG) grids is an essential part of the worldwide hydrogen strategies, in addition to the construction of new pipelines. In this context, the transportation of hydrogen is fundamental different from NG as hydrogen can be absorbed into the pipeline material. Given the well-known effects of hydrogen embrittlement, the compatibility of the materials for the intended pipelines must be investigated (typically low alloy steels in a wide range of strengths and thicknesses). However, pipelines require frequent maintenance, repair or the need for installation for further outlets. In some cases, it is necessary to perform welding on or onto the pipelines while they are still in service, i.e. with active gas flow under high pressure, e.g. such as the well-known “hot tapping”, see Fig. 1a. This in-service welding causes challenges for hydrogen operations in terms of additional hydrogen absorption during welding and the material compatibility. The challenge can be roughly divided into the possible austenitization of the inner pipe material exposed to hydrogen, which can lead to sufficient hydrogen absorption, and the welding itself, which causes an increased temperature range. Both lead to a significant increase in hydrogen solubility and diffusivity of the respective materials compared to room temperature. In this context, knowledge about hot tapping on hydrogen pipelines is scarce due to the lack of operating experience. Fundamental experimental investigations are required to investigate the transferability from NG to hydrogen pipeline grids. For this reason, the present study introduces a specially designed mock-up / demonstrator concept for the realistic assessment of the welding processing conditions, see Fig. 1b. The mock-up was designed to enable in-situ temperature measurement during welding as well as ex-post extraction of samples for the quantification of the absorbed hydrogen concentration, see Fig. 1c. For safety measures, the necessary pressurized hydrogen volume was limited by the insertion of a solid cylinder ensuring a 1 cm hydrogen gas layer. Welding experiments on the pressurized mock-ups with the diameters DN50 and DN200 have shown that the austenitization temperature can be reached on the inner surface of the pipeline, especially on thinner-walled pipelines, using current welding practices. This corresponds to an increased hydrogen uptake in the welded area of several ppm T2 - 1st Conference on Hydrogen in Materials Science and Engineering (H2-MSE) CY - Siegburg, Germany DA - 11.02.2025 KW - Hydrogen KW - Pipeline KW - In-service welding KW - Component test PY - 2025 AN - OPUS4-62544 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - Effect of high-pressure hydrogen environment on the physical and mechanical properties of elastomers N2 - This presentation deals with the exposure of HNBR rubbers to high pressure hydrogen (100 MPa) at 120 °C for 7 and 21 days under static conditions followed by characterization of their physical and mechanical properties.The core areas include swelling, rapid gas decompression, dynamic mechanical analysis (DMA), tensile strength and compression set properties. This study will assist in expanding the knowledge base of elastomer compatibility with hydrogen and therefore contribute significantly to the selection and development of polymer materials deploying hydrogen as a future energy carrier. T2 - EHEC European Hydrogen Energy Conferecne 2022 CY - Madrid, Spain DA - 18.05.2022 KW - Rubbers KW - Hydrogen KW - Characterization PY - 2022 AN - OPUS4-62084 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - Fretting wear of elastomer materials in hydrogen N2 - This paper presents an experimental study on the fretting wear behavior of two types of cross-linked hydrogenated acrylonitrile butadiene rubbers against 316L steel ball in hydrogen environment. Furthermore, aging experiments were conducted for 7 days under static conditions in 100 MPa hydrogen. The influences of hydrogen pressure as well as the aging exposure on the fretting behavior are discussed by means of surface analyses and well as material properties. T2 - WHEC-2022, 23rd World Hydrogen Energy Conference CY - Istanbul, Turkey DA - 26.06.2022 KW - Rubbers KW - Hydrogen KW - Fretting PY - 2022 AN - OPUS4-62086 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - Fretting behavior of elastomer materials in hydrogen N2 - This presentation deals with the fretting wear behavior of elastomer materials (two types of cross-linked hydrogenated acrylonitrile butadiene rubbers) against 316L steel ball in hydrogen environment. Furthermore, aging experiments were conducted for 7 days under static conditions in 100 MPa hydrogen. Fretting tests revealed the wear of the polymer decreases with increasing hydrogen pressure. After high pressure hydrogen exposure, the fretting process is characterized by increased adhesion due to elastic deformation, leading to partial slip. T2 - 63rd German Tribology Conference 2022 CY - Göttingen, Germany DA - 26.09.2022 KW - Fretting KW - Rubbers KW - Hydrogen PY - 2022 AN - OPUS4-62082 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - Comparison of the sliding behaviour of several polymers in hydrogen N2 - The work presented here deals with the friction and wear behaviour of polymer materials in hydrogen. Commercially available grades of PEEK, PA, PPA, PAI, PI and PBI were investigated at room temperature in air and hydrogen gas (H2) as well as in liquid hydrogen at - 253°C (LH2). T2 - 7th World Tribology Congress, WTC 2022 CY - Lyon, France DA - 10.07.2022 KW - Friction KW - Wear KW - Polymers KW - Hydrogen KW - Cryogenic PY - 2022 AN - OPUS4-62087 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - Effect of hydrogen pressure on the fretting behavior of elastomers N2 - In this study, the fretting behavior of several elastomer materials against 316L were evaluated in air and hydrogen environment up to 10 MPa. Furthermore, aging experiments were conducted for 7 days under static conditions in 100 MPa hydrogen and the physical and mechanical properties of the rubber materials were examined before and after hydrogen exposure. Fretting tests revealed that the wear of these compounds is significantly affected by the hydrogen environment compared to air, especially with NBR grades. After aging experiment, the friction response of HNBR grades is characterized by increased adhesion due to elastic deformation, leading to partial slip. T2 - 4th Int. Conf. on Polymer Tribology, PolyTrib 2022 CY - Stockholm, Sweden DA - 05.12.2022 KW - Hydrogen KW - Fretting KW - Elastomers PY - 2022 AN - OPUS4-62006 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - Polymer materials in hydrogen N2 - This presentation provides an overview of the applications and challenges related to polymer materials in hydrogen. The effects of hydrogen on polymers are described and test methods to evaluate the interactions between polymers and hydrogen are presented along with case studies. T2 - Masterstudiengang Wasserstofftechnologien DIU CY - Online meeting DA - 25.08.2023 KW - Hydrogen KW - Polymers PY - 2023 AN - OPUS4-61964 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - Effect of hydrogen pressure on the fretting behavior of elastomers N2 - In this study, the fretting behavior of several elastomer materials against 316L were evaluated in air and hydrogen environment up to 10 MPa. Furthermore, aging experiments were conducted for 7 days under static conditions in 100 MPa hydrogen and the physical and mechanical properties of the rubber materials were examined before and after hydrogen exposure. Fretting tests revealed that the wear of these compounds is significantly affected by the hydrogen environment compared to air, especially with NBR grades. After aging experiment, the friction response of HNBR grades is characterized by increased adhesion due to elastic deformation, leading to partial slip. T2 - ITC 2023: 9th International Tribology Conference 2023 CY - Fukuoka, Japan DA - 26.09.2023 KW - Hydrogen KW - Fretting KW - Elastomers PY - 2023 AN - OPUS4-61962 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - Comparative evaluation of the sliding performance of polymers materials in gaseous and liquid hydrogen N2 - The focus of this study is to evaluate the influence of hydrogen on the friction and wear behavior of a wide range of commercially available polymer materials. Thereby, Filled and unfilled polymers from different suppliers were evaluated at room temperature in air and hydrogen gas (H2) as well as in liquid hydrogen at - 253°C (LH2). T2 - 2023 Hydrogenius & I2CNER Tribology Symposium CY - Fukuoka, Japan DA - 03.02.2023 KW - Hydrogen KW - Tribology KW - Cryogenic KW - LH2 KW - Polymers PY - 2023 AN - OPUS4-61961 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Tiebe, Carlo T1 - Hydrogen Sensing - Sensors for Safety and Process Control in Hydrogen Technologies N2 - The success of this energy transition and the efficient utilization of green hydrogen as a pristine energy carrier hinge upon the cultivation of hydrogen readiness, swift market expansion, and the establishment of crucial value chains within national and European contexts. Paramount to these objectives are reliable quality and safety standards, essential for ensuring supply safety, environmental compatibility, and instilling confidence in these technologies. In the realm of safety management systems, gas sensors emerge as vital components for detecting hydrogen. This presentation delves into the imperative role of hydrogen systems, emphasizing their capability to monitor and control operations, issue warnings, signal hazardous conditions, and sound alarms. It explores the intricate landscape of functional safety considerations and addresses the challenges associated with measurement uncertainty in sensor testing. A diverse array of sensors catering to hydrogen, pressure, temperature, and flow are available, each contributing significantly to the safety and efficiency of hydrogen technologies. Applications are envisaged to adhere meticulously to quality infrastructural regulations, codes, and standards, ensuring seamless integration and operation within the broader hydrogen ecosystem. This discussion underscores the ubiquitous presence of sensor systems across various fields within hydrogen technologies, illustrating their multifaceted contributions to safety, reliability, and overall success in realizing the transformative potential of green hydrogen. T2 - Joint European Summer School JESS 2024 CY - Vravrona, Greece DA - 16.09.2024 KW - H2Safety@BAM KW - Hydrogen KW - Sensor KW - Sensor technology KW - Safety KW - Process control PY - 2024 AN - OPUS4-61677 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kaiser, Sebastian T1 - Repair welding of in-service hydrogen pipelines - concepts and challenges N2 - Hydrogen is set as the energy carrier of tomorrow for a more sustainable fossil fuel free future. As this necessitates a reliable transport infrastructure, repurposing of the existing natural gas grid is planned. With regards to the well-known effect of hydrogen embrittlement, the compatibility of utilized materials must be investigated. First comprehensive studies on pipeline material hydrogen compatibility indicate that these materials can be applied to a certain extent. Nonetheless, the material compatibility is currently of high interest and focus of numerous research projects worldwide. However, pipelines require frequent maintenance and repair work. As part of these, in some cases it is necessary to do weldments onto pipelines while they are pressurized. This in-service welding introduces additional challenges for the material compatibility. Due to the resulting high temperatures, the metallurgical changes in the material and of course the presence of high-pressure hydrogen in the pipeline, additional investigations need to be conducted to ensure that no critical material degradation because of increased hydrogen absorption occurs and an overall material compatibility is given. For this reason, the present paper introduces in-service welding on pipelines. An overview of current research projects that deal with the application of in-service welding specifically on hydrogen pipelines and the emerging problems when applying these techniques on hydrogen pipelines is given. Methods of material testing, their limits and possible solutions are presented and discussed. T2 - 15th International Pipeline Conference and Exhibition (IPCE 2024) CY - Calgary, Alberta, Canada DA - 23.09.2024 KW - Hydrogen KW - In-Service KW - Pipelines KW - Repair welding PY - 2024 AN - OPUS4-61471 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Erxleben, Kjell T1 - Challenges and difficulties in repair welding procedures on in-service hydrogen pipelines N2 - Hydrogen as an energy carrier plays a key role in tomorrow's energy transition. For effective use of hydro-gen as energy carrier the construction of the corresponding infrastructure is of utmost importance. In that context, large diameter long-distance transmission pipelines will form the so-called hydrogen backbone in the European Union with service pressures up to 100 bar (e.g., depending on national regulations). From an economically and ecologically point of view, a major goal is to repurpose the existing natural gas (NG) infra-structure to minimize the need to install new pipelines. To ensure the safety, reliability and integrity of this future hydrogen infrastructure repair welding or further welding of branch pipes etc. can be necessary at in-service conditions, meaning a permanent flow of pressurized hydrogen while executing the repair procedure. The reason is that a shut-down of large diameter pipelines is not easy or sometimes merely impossible. In fact, as long, as no oxygen enters the pipeline, there will neither be any combustion nor (in the worst-case scenario) explosion. The special techniques like hot tapping or stoppling are state-of-the-art for NG and oil pipeline grids. Currently, it is not finally clarified if repair welding procedures for NG pipelines can be trans-ferred to pure hydrogen pipelines. In opposite to NG, hydrogen can be way easier absorbed to the pipeline steels and diffuses through the material. If it accumulates in susceptible regions, i.e., in the welded joint or heat affected zone, hydrogen assisted embrittlement could occur and lead to loss of integrity or even cata-strophic failure of the pipeline. For example, requires the planned welding procedure a preheating and maintenance of the weld joint of up to 300°C for up to several hours at the outer. This temperature is way higher compared to the typical service temperature of max. 60°C at operational pressures of up to 100 bar. In accordance to API 941, these low-alloyed pipeline steels are subjected to short-term service loads, which they are not designed for. Another considerable fact is that if the weld seam is attached to the pipeline, the temperature especially for small wall thickness can be easily above the austenitization temperature. It is well known that austenite has a way higher hydrogen solubility compared e.g. to ferrite/bainite microstructure of the low-alloyed steel. Current studies indicate a remarkable increase of the hydrogen ingress dur-ing the austenitization from the inner pipe wall. It must be answered if a critical material degradation because of increased hydrogen uptake due to in-service welding procedures is likely to occur. T2 - MPA Seminar 2024 CY - Stuttgart, Germany DA - 08.10.2024 KW - In-service KW - Pipeline KW - Hydrogen KW - Welding KW - Repair PY - 2024 AN - OPUS4-61468 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Grimault de Freitas, Tomás T1 - Comprehensive standardization of the hollow specimen method for tests in high pressure hydrogen gas N2 - As the world moves towards a decarbonised economy, the demand for sustainable and low-carbon alternatives is rapidly increasing. Hydrogen plays an important role in this transition, but in order to make the most of hydrogen as an energy carrier, a comprehensive understanding of its impact on the integrity of structural materials is necessary. Metallic materials, mostly steels, are the most regularly used structural materials in various components throughout the hydrogen supply chain. Ensuring their sustainable and safe use in hydrogen technologies is a crucial factor in the development of the hydrogen economy. This is particularly important since hydrogen can promote crack formation and ultimately lead to premature failure in these materials when combined with mechanical load. This process is commonly known as Hydrogen Embrittlement and can occur in almost all the steels used for the hydrogen technologies. Extensive materials qualification is needed for the rapid implementation of hydrogen technologies, however, most accepted, and standardised test methods for determining the effect of gaseous hydrogen on metallic materials describe complex and costly procedures that are only available to a very limited extent worldwide. The hollow specimen technique is a simple and economical method that has the potential to overcome the limitations of the current methods and complement them for qualifying metallic materials under high-pressure hydrogen gas. In this method, an axial hole is drilled in a tensile specimen, which is then filled with hydrogen gas, sealed, and placed in a standard testing machine. This method requires significantly lower amounts of hydrogen, resulting in fewer safety measures and no need for complex equipment or a specialised laboratory, unlike the conventional autoclave technique. The technique's low investment and testing costs, simple operation, and shorter testing time make it optimal for widespread use around the world, thereby increasing the output of results. Initial studies have demonstrated the feasibility of assessing hydrogen effects in metallic materials using the hollow specimen technique. This led to the establishment of the committee ISO/TC 164/SC 1/WG 9 “Tensile testing, method in high-pressure hydrogen environment“ to standardise the method, however, there are open questions that currently prevent the technique from being standardised for hydrogen testing. These open questions relate to specimen geometry, inner hole surface and gas quality and are being addressed in the H2HohlZug project. Here, the aim is to systematically address and close the gaps towards the standardisation of this technique for tests with hydrogen. This contribution presents the structure and milestones of the project, followed by initial results regarding the optimisation of the specimen geometry, as well as the influence of different manufacturing and finishing processes on the inner hole surface of the hollow specimen and its response to hydrogen effects. T2 - TestXpo | 32nd International Expo for Materials Testing CY - Ulm, Germany DA - 21.10.2024 KW - Hydrogen KW - Hydrogen Embrittlement KW - High-Pressure Gaseous Gas KW - Hollow Specimen Technique KW - H2HohlZug KW - TransHyDE KW - Standardisation KW - Tensile Test PY - 2024 AN - OPUS4-61453 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - Polymer tribology in cryogenic hydrogen N2 - In this presentation, an overview of polymer tribology in cryogenic hydrogen is given along comparison with other environments. T2 - Hydrogenius Symposium 2024 CY - Kyushu University Ito Campus, Japan DA - 12.09.2024 KW - Hydrogen KW - Friction KW - Wear KW - Polymer materials KW - Cryogenic PY - 2024 AN - OPUS4-61426 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - On the way to sustainable and hydrogen compatible sealing materials N2 - In this contribution, the sliding performance of newly formulated polymer materials with improved sustainability are investigated and compared with conventional materials. Tribological tests were performed in hydrogen at ambient temperature as well as cryogenic medium. The samples were arranged in a pin-on-disk configuration with a flat pin sliding against a rotating austenitic steel disk. The friction and wear mechanisms are described and discussed by means of surface analyses. T2 - PolyTrib 2024 CY - Portoroz, Slowenia DA - 03.10.2024 KW - High-performance polymers KW - Sliding wear KW - Hydrogen KW - Cryogenic PY - 2024 AN - OPUS4-61419 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Theiler, Geraldine T1 - An overview of tribology in gaseous Hydrogen N2 - In this presentation, an overview in gaseous hydrogen is given along with examples related to metal, coatings, polymers and rubbers materials. T2 - International Seminar, Hydrogen & Materials 2024 CY - Espoo, Finland DA - 06.06.2024 KW - Hydrogen KW - Friction KW - Wear KW - Materials PY - 2024 AN - OPUS4-61408 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Component test for simplified testing of hydrogen‐assisted delayed cold cracking of high‐strength, submerged arc‐welded offshore steel structures N2 - Offshore Wind Turbines (OWT) are a key factor in tomorrow's sustainable energy generation. The ever-increasing installation depth and weight of OWTs require suitable foundation concepts such as monopiles or tripods. Typically, mild steels such as S420ML are used with plate thicknesses of up to several hundred mm, resulting in high restraints in the welded joints. The large plate thickness requires high-efficiency welding processes such as submerged arc welding (SAW) with multiple wires. Due to the very high stiffness and plate thickness of the large-scale offshore structure, a susceptibility to time-delayed hydrogen assisted cracking (HAC) may occur. The evaluation of this crack susceptibility is very complex due to the component size and stiffness of real offshore structures. For this purpose, a near-component test geometry was developed to transfer the real stiffness conditions to laboratory (i.e. workshop) scale. The 350 kg mock-up studied consisted of heavy plates (thickness 50 mm, seam length 1,000 m) joined by a 22-pass submerged-arc weld. Additional stiffeners simulated the effect of high restraint or shrinkage restraint of the weld. Extreme scenarios of hydrogen absorption during welding were simulated by using flux in dry (HD < 5 ml/100g Fe) and wet (HD > 15 ml/100g Fe) conditions. Weld residual stresses were determined using a robotic X-ray diffractometer. Areas of critical tensile residual stress (at the level of the yield strength) were found in the weld metal and in the heat affected zone, suggesting that these weld sub-zones are the most critical in the case of hydrogen ingress. To identify possible delayed cracking, the welds were tested by phased array ultrasonic testing (PAUT) after welding, 6 h, 12 h, 24 h, and a maximum of 48 h. Summarized, no significant occurrence of HAC was detected, indicating the high crack resistance of the welded joint, i.e., a suitable combination of base material, welding consumable and parameters. T2 - MPA Seminar 2024 - Materials, Processes, Applications CY - Stuttgart, Germany DA - 08.10.2024 KW - Hydrogen KW - Offshore wind turbine KW - Component test KW - Submerged arc welding KW - Minimum waiting time PY - 2024 AN - OPUS4-61323 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Ebell, Gino T1 - Prestressed Concrete Structures with ConcentratedTendons- Structural Damage due to Hydrogen-Induced Stress Corrosin Cracking N2 - In the course of the deconstruction of the "Bridge of the 20th anniversary of the GDR" at the Altstädter Bahnhof in Brandenburg a. d. Havel, new information on the initiation of hydrogen-induced stress cracks was obtained. BAM was commissioned by the Brandenburg State Road Administration to participate in a corresponding joint project which is financed by the Federal Ministry for Digital and Transport. The added value of the new information gained in this project goes beyond the specific structure. It describes unexpected new damage patterns that can be transferred to other structures with concentrated tendons (tendon block method and Baur-Leonhardt method) and were previously unknown in this form. These should be made known to other developers to enable them to initiate any necessary actions. T2 - Consec 2024 CY - Chennai, India DA - 24.09.2024 KW - Corrosion KW - Spannstahl KW - Hydrogen KW - Korrosion PY - 2024 AN - OPUS4-61305 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Grimault de Freitas, Tomás T1 - Closing the gaps towards the Standardisation of the Hollow Specimen Method for Tests in High-Pressure Hydrogen Gas N2 - Metallic materials, mainly steels, are the most commonly used structural materials in various components throughout the hydrogen supply chain. Ensuring their sustainable and safe use in hydrogen technologies is a crucial factor in the development of the hydrogen economy. This is particularly important since hydrogen can promote crack formation and ultimately lead to premature failure in these materials when combined with mechanical load. This process is commonly known as Hydrogen Embrittlement and can occur in a large number of steels used for the hydrogen technologies.[1] Extensive materials qualification is required for the rapid implementation of hydrogen technologies, however, most accepted, and standardised test methods for determining the effect of gaseous hydrogen on metallic materials describe complex and costly procedures (e.g. in-situ autoclave technique) that are only available to a very limited extent worldwide. The hollow specimen technique is a simple and economical method that has the potential to overcome the limitations of the current methods and complement them for qualifying metallic materials under high-pressure hydrogen gas. Unlike the conventional autoclave technique, this method requires significantly lower amounts of hydrogen, resulting in fewer safety measures and no need for complex equipment or a specialised laboratory. The technique's low investment and testing costs, simple operation, and shorter testing time make it an optimal for widespread use around the world, thereby increasing the output of results. Initial studies have demonstrated the feasibility of assessing hydrogen effects in metallic materials using the hollow specimen technique. This led to the establishment of an ISO committee to standardise the method, however, there are open questions that currently prevent the technique from being standardised for hydrogen testing. These open questions relate to specimen geometry, inner hole surface and gas quality and are being addressed in the TransHyDE - H2HohlZug project. The aim of the project is to systematically address and close the gaps towards the standardisation of this technique for tests in hydrogen. The project is divided into four work packages. First, the elastic-plastic behaviour of a hollow tensile specimen is compared with that of a conventional solid tensile specimen of identical external dimensions using finite element methods (3D-FEM) and subsequently validated by experimental results. In the second, the influence of the inner hole surface quality of the specimen on the hydrogen effects is evaluated. Five different methods of producing the inner axial hole were chosen to ensure different average roughness values and residual stresses (drilling vs. EDM), and also to ensure a good representation of the more common and easily accessible processes (drilling and reaming) to the more complex ones (EDM and honing). Next, the influence of gas purity (different compositions) and purging process (different routines) is evaluated. Finally, an optimal specimen geometry, inner hole production process, gas quality and purging process are proposed from each working package and its reproducibility and repeatability is evaluated in a round robin with national and international partners. This contribution presents the structure and milestones of the project, followed by initial results regarding the influence of different manufacturing and finishing processes on the inner hole surface of the hollow specimen and its response to hydrogen effects. T2 - MPA Seminar 2024 - Materials, Processes, Applications CY - Stuttgart, Germany DA - 08.10.2024 KW - Hydrogen KW - Hydrogen Embrittlement KW - Tensile Test KW - High-Pressure Gaseous Hydrogen KW - Hollow Specimen Technique KW - Standardisation KW - TransHyDE KW - H2HohlZug PY - 2024 AN - OPUS4-61286 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kröll, Mirco T1 - Harmonised tribological testing of polymers in hydrogen N2 - The focus of this work is to study the tribological performance of polymers in hydrogen atmosphere. Additionally, tests were carried out with up to three different tribometers at two institutions. The challenge to compare and harmonise equipment, procedures, and methods is an important part of the study. T2 - PolyTrib 2024 CY - Portoroz, Slovenia DA - 03.10.2024 KW - Hydrogen KW - Tribometer KW - Comparability KW - Harmonisation KW - Oil-coupled compounds PY - 2024 AN - OPUS4-61224 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Diffusion and trapping of gaseous hydrogen charged CoCrFeMnNi-HEA vs. austenitic steel AISI 316L at pressure up to 1000 bar N2 - First studies on the mechanical behavior of high-entropy alloys (HEAs) in high-pressure hydrogen environment are available. In contrast, the underlying hydrogen absorption, diffusion and trapping in these HEAs like the Cantor-alloy was less in the scientific scope so far. For that reason, the CoCrFeMnNi-HEA was compared to a conventional AISI 316L austenitic steel, by exposing to high-pressure hydrogen charging at 200 bar and very-high pressure at 1,000 bar. Thermal desorption analysis (TDA) was applied with different heating rates (0.125 K/s to 0.500 K/s). The underlying TDA spectra were analyzed in terms of a reasonable peak deconvolution to into a defined number of peaks and the calculation of the activation energies for the respective and predominant hydrogen trap sites. Both materials show a comparable hydrogen diffusivity. The obtained activation energies suggest that in case of the CoCrFeMnNi-HEAs an interaction of the austenitic phase as well as the direct atomic bonding of hydrogen to the metal atoms are the dominant traps, since “impurities” such as carbides or inclusions are only present in trace amounts. Available literature suggests that the Cr and Mn-content is here of special interest for the direct hydrogen bonding at solute atoms. T2 - MSE 2024: International Materials Science and Engineering Congress CY - Darmstadt, Germany DA - 24.09.2024 KW - High-entropy alloy KW - Hydrogen KW - Trapping KW - Diffusion KW - High-pressure charging PY - 2024 AN - OPUS4-61156 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Welding of in service hydrogen pipelines for repair and maintenance purposes Concepts and Challenges N2 - Hydrogen will make a decisive contribution to a sustainable large-scale energy supply, the transport of which will be based on long-distance pipeline grids. Previous material compatibility studies have shown that the currently used low-alloy pipe steels are generally suitable for hydrogen pipelines. However, this cannot be directly transferred to the case of repair welding. For technical and economic reasons, welding work on hydrogen pipelines in service is usually carried out during operation under continuous pressure and gas flow. In this context, concepts such as hot tapping and stoppling are well established in natural gas (NG) grids and crude oil transportation. In hot tapping, a pressurized pipeline is drilled by flanging a sealed, pressure-tight system consisting of a shut-off valve and drilling equipment. For this purpose, sleeves (made of preformed cylindrical half-shells) must be welded by longitudinal seams and then welded to the product-carrying pipeline by circumferential girth welds. Preheat temperatures of approximately 100 °C must be maintained for most manual metal arc (MMA) / shielded metal arc welding (SMAW) and 250 °C for the interpass temperature in multi-pass welding. This is particularly important for thin-walled pipelines because the austenitizing temperature is exceeded on the inside of the pipeline when the girth welds are welded. As a result, significantly higher hydrogen absorption in the pipeline steel is expected, with possible degradation of mechanical properties or cracking. T2 - MSE 2024: International Materials Science and Engineering Congress CY - Darmstadt, Germany DA - 24.09.2024 KW - Hydrogen KW - Repair welding KW - Pipelines KW - In-service PY - 2024 AN - OPUS4-61155 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Development of a component test for assessment of delayed hydrogen assisted cracking susceptibility of thick walled submerged arc welded high strength offshore steels N2 - Offshore Wind Turbines (OWT) are a key factor in tomorrow's sustainable energy generation. The ever-increasing installation depth and weight of OWTs require suitable foundation concepts such as monopiles or tripods. Typically, mild steels such as S420ML are used with plate thicknesses of up to several hundred mm, resulting in high restraints in the welded joints. The large plate thickness requires high-efficiency welding processes such as submerged arc welding (SAW) with multiple wires. Due to the very high stiffness and plate thickness of the large-scale offshore structure, a susceptibility to time-delayed hydrogen assisted cracking (HAC) may occur. The evaluation of this crack susceptibility is very complex due to the component size and stiffness of real offshore structures. For this purpose, a near-component test geometry was developed to transfer the real stiffness conditions to laboratory (i.e. workshop) scale. The 350 kg mock-up studied consisted of heavy plates (thickness 50 mm, seam length 1,000 m) joined by a 22-pass submerged-arc weld. Additional stiffeners simulated the effect of high restraint or shrinkage restraint of the weld. Extreme scenarios of hydrogen absorption during welding were simulated by using flux in dry (HD < 5 ml/100g Fe) and wet (HD > 15 ml/100g Fe) conditions. Weld residual stresses were determined using a robotic X-ray diffractometer. Areas of critical tensile residual stress (at the level of the yield strength) were found in the weld metal and in the heat affected zone, suggesting that these weld sub-zones are the most critical in the case of hydrogen ingress. To identify possible delayed cracking, the welds were tested by phased array ultrasonic testing (PAUT) after welding, 6 h, 12 h, 24 h, and a maximum of 48 h. Summarized, no significant occurrence of HAC was detected, indicating the high crack resistance of the welded joint, i.e., a suitable combination of base material, welding consumable and parameters. T2 - MSE 2024: International Materials Science and Engineering Congress CY - Darmstadt, Germany DA - 24.09.2024 KW - Hydrogen KW - Offshore wind turbine KW - Component test KW - Submerged arc welding KW - Minimum waiting time PY - 2024 AN - OPUS4-61154 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Scarponi, Giordano T1 - Numerical Simulation Of Cryogenic Liquid Hydrogen Tanks With Multilayer Insulation Exposed to Fire N2 - In the ongoing energy transition, hydrogen has emerged as a promising alternative energy carrier with a reduced environmental impact. Among the possible solutions to store hydrogen onboard vehicles, cryogenic tanks equipped with multilayer insulation (MLI) appear to be one of the most effective in ensuring high volumetric energy density. MLI systems consist of several layers of low-emissivity material (radiative layers), typically aluminum or aluminum-coated polyester, interleaved with low thermal conductivity spacers to avoid direct contact between the radiative layers. In cryogenic tank applications, these are enclosed within the vessel double-walled shell, working under high-vacuum conditions. Among the insulation systems available nowadays, MLI-based ones have the smallest volume requirements and the lowest weight. Thanks to these features, MLI appears as the preferable choice in sectors where space and weight constraints play a crucial role (e.g., in the transportation sector). The widespread deployment of LH2 new technologies poses also challenging questions related to the hazardous properties of hydrogen. The accidental loss of integrity of cryogenic LH2 tanks might lead to extremely dangerous phenomena, such as Boiling Liquid Expanding Vapour Explosions (BLEVE), Fireball, and Rapid Phase Transition (RPT). One potential scenario that could give rise to this situation is exposure to an external heat source such as a fire triggered by a road accident. Real-scale fire test results suggest that the insulation performance of MLI systems may undergo severe degradation when these are subjected to high temperatures, leaving the tank almost unprotected and leading to failure in a relatively short time. In this framework, the availability of models able to simulate the tank response to fire exposure is crucial to ensure a safe design and support emergency response planning. Several CFD and lumped models originally developed for pressurized and atmospheric tanks were extended to cryogenic vessels. However, these provide results in line with experimental data only if the insulation system's equivalent thermal conductivity is fine-adjusted to higher values with respect to normal operating conditions. These models do not integrate, in fact, the description of MLI thermal degradation as a result of fire exposure, which was demonstrated to play a crucial role in determining the response of the cryogenic liquid hydrogen tank. On the other hand, MLI heat transfer models currently available in the literature are suitable for normal operative conditions only and do not address the material behavior under fire exposure. This work presents an innovative lumped model to simulate the thermal response of MLI-insulated cryogenic hydrogen tanks in fire scenarios. In particular, the proposed approach enables the prediction of MLI loss of insulation performances due to fire-induced thermal degradation, overcoming the limitations of currently available models. The MLI degradation model is based on the well-established layer-by-layer approach and integrated with sub-models to estimate the material deterioration due to thermal load. Several sub-models were defined to account for different MLI materials. In particular, for polyester-based MLIs, the deterioration of each layer is defined by the apparent kinetic of thermal degradation retrieved from Thermo-Gravimetric-Analysis (TGA) tests. For aluminum-based MLI, each radiation layer is assumed to vanish when its temperature reaches the melting point of the material. The model was applied to several case studies addressing different types of MLI (i.e., both polyester-based and aluminum-based ones) and fire scenarios to assess the effect on the heating rate and pressure build-up of the tank lading. The analysis allowed for the performance comparison of the studied MLIs, providing valuable information to support the emergency management of accidental scenarios involving liquid-hydrogen cryogenic tanks. Moreover, the results obtained can be used to define mitigation measures to protect the integrity of cryogenic tanks equipped with MLI. T2 - Spring24+20thGCPS CY - New Orleans, Louisiana, USA DA - 24.03.2024 KW - Multilayer Insulation KW - Fire KW - Hydrogen KW - Liquefied Natural Gas KW - Insulation PY - 2024 AN - OPUS4-61078 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Nietzke, Jonathan T1 - Evolution of tensile testing methodologies for hydrogen embrittlement in austenitic steels: a comparative study N2 - The energy transition towards hydrogen utilisation has increased the demand for reliable testing methods to evaluate the susceptibility of metallic materials to hydrogen degradation. However, traditional electrochemical pre-charging techniques have limitations in represent-ing realistic gaseous hydrogen exposure conditions. This study presents three comparative analyses of tensile testing methodologies, focusing on the differences between electrochem-ical pre-charging, gaseous pre-charging, and in-situ testing using hollow specimens for aus-tenitic steels AISI 304L and 316L type austenitic steels. Based on the results obtained, the first comparison reveals that electrochemically pre-charged and gaseously pre-charged specimens exhibit different behaviours regarding the impact on the mechanical properties. This effect can be retraced to the varying distribution of hydrogen throughout the specimens. Although comparable embrittlement was observed for similar hydrogen concentrations, the relationship appears to be non-systematic. The second comparison evaluates the performance of pre-charged hollow specimens (300°C, 100 bar, 21 days) in comparison to hollow specimens tested in-situ under 200 bar hydrogen during slow strain rate tensile tests (SSRT). While pre-charged specimens show a slight de-crease in elongation at fracture and a noticeable decrease in reduction of area (RA), in-situ tested specimens exhibit significantly more pronounced embrittlement. This is in accord-ance with the results of Michler et. al. In the third comparison, geometry effects between pre-charged conventional and pre-charged hollow specimens are explored. In this case, the hydrogen effect appears to be of the same order of magnitude for both specimen types, although some differences are ob-served. The study's findings underscore the importance of considering differences between test methods when assessing materials’ compatibility with hydrogen. It specifically emphasises the need for in-situ testing with gaseous hydrogen to better represent real conditions in ap-plications within the hydrogen sector. Furthermore, the study provides an initial compari-son between conventional and hollow specimens, demonstrating their capability to reveal hydrogen effects. However, additional research is essential to enhance the comparability of results yielded by these testing methods. T2 - European Conference on Fracture 2024 CY - Zagreb, Croatia DA - 26.08.2024 KW - Hollow Specimen Technique KW - Hydrogen KW - Austenitic Stainless Steel KW - Hydrogen Testing KW - AISI 316L PY - 2024 AN - OPUS4-60929 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Konert, Florian T1 - The applicability of the hollow specimen technique for testing various metals under high pressure hydrogen atmosphere N2 - The transition to a decarbonised economy will require large amounts of hydrogen over a broad variety of applications. The use of hydrogen poses high safety requirements as hydrogen can be absorbed by metallic materials and result in hydrogen embrittlement under certain condi-tions. For this reason, interactions of gaseous hydrogen and metallic materials are of high sci-entific and industrial interest. Slow strain rate tensile (SSRT) tests are commonly used to evaluate the hydrogen-induced ductility loss of alloys. However, the current standardised test method describes a complex and expensive procedure with limited availability worldwide. The hollow specimen technique promises huge potential for scaling suitable in-situ testing infra-structure and is currently under intensive development in several institutes around the world. As this method has only gained significant attention in the last decade, there are varying interpretations, particularly when testing materials with vastly different mechanical properties. Most available literature focuses on common steels used in hydrogen and natural gas piping systems. The present work provides an overview of the widespread applicability of hollow specimens in evaluating the effect of high-pressure hydrogen on the tensile properties of vari-ous metallic materials. The research presented includes Near-Net shape produced additively manufactured (AM) AISI 316 L, ferritic X65 steel, its weld seam, and solution annealed and hardened 100Cr6 steel. T2 - European Conference on Fracture 2024 CY - Zagreb, Croatia DA - 26.08.2024 KW - Hydrogen KW - Hollow specimen technique KW - SSRT PY - 2024 AN - OPUS4-60912 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Naster, Maximilian T1 - Experimental and Numerical Analyses for the Evaluation of Hydrogen as an Energy Source for Thermal Testing of Transport Packages of Radioactive Material N2 - In this paper we present a new hydrogen-based test rig for an ongoing feasibility study of using hydrogen as an energy source for the thermal testing of transport packages containing radioactive materials. The test rig will be capable of combusting hydrogen for a wide range of different burner geometries, mass flows and if necessary hydrogen blends. As this type of fire test according to the IAEA boundary conditions does not yet exist, a large number of preliminary investigations, safety assessments and calculations must be carried out in order to develop a viable concept for hydrogen fires. In the first step of the feasibility study, the temperature, structure, and radiation of various hydrogen flames are surveyed. In future works, the results will make it possible to design burner frames that are suitable for fire reference tests in order to make comparisons with pool and propane fires used in assessment procedures today. In parallel comparative numerical simulations are conducted to model the thermal behaviour of hydrogen flames using the software package Ansys®. On the one hand, the numerical simulations support the experiments by providing an overview of numerous parameters and the measuring range; on the other hand, they will help with the design of the burner frame in future work. This paper gives an overview in the design and capabilities of the test rig. Furthermore, the results of the parameter studies show that burner geometry and mass flow provide a significant design margin for the thermal shape of the hydrogen flames. In addition, the results of the initial numerical calculations will be used to determine the necessary sensors, the positions, and their operating range. Only the optimal interaction allows a controlled system that permits user-defined hydrogen fires. T2 - PVP2024, Pressure Vessels & Piping Conference CY - Bellevue, Washington, USA DA - 29.07.2024 KW - Hydrogen KW - Fire KW - IAEA Regulations KW - CFD KW - Burner PY - 2024 AN - OPUS4-60855 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Karapanagiotis, Christos T1 - Monitoring hydrogen composite pressure vessels using surface applied distributed fiber optic sensors N2 - We report on surface-applied distributed fibre optic sensors for monitoring composite pressure vessels designed for hydrogen storage. Previous reports have revealed that integrating optical fibres within vessel composite structures effectively enables the monitoring of structural behavior throughout their lifetime. However, integrating optical fibres during the manufacturing process is complex and time-consuming. Therefore, we aim to simplify this process by attaching the optical fibres to the vessel’s surface. This method is significantly more timeefficient than the integration process and can be applied to any vessel. Our results demonstrate that surface-applied fibre optic sensors can detect and precisely localise damage. Additionally, signs of damage can be recognised even before the damage occurs. Predictive maintenance using fibre optic sensors could reduce premature maintenance costs and periodic inspections while increasing safety and extending the vessel’s useful service life. The role of machine learning in predictive maintenance is also discussed. T2 - 20th Sensors & their Applications Conference CY - Limerick, Ireland DA - 11.08.2024 KW - Hydrogen KW - Fiber optic sensors KW - Composites KW - Machine learning KW - Structural health monitoring PY - 2024 AN - OPUS4-60831 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Kaiser, Sebastian A1 - Rhode, Michael T1 - Repair welding of pressurized in-service hydrogen pipelines: A review on current challenges and strategies N2 - As energy carrier of the future, green hydrogen can make a decisive contribution to a sustainable energy supply. Particularly important is the decarbonization of heavy industry. Therefore, a reliable supply of hydrogen must be guaranteed. A hydrogen pipeline grid can achieve this purpose. In Europe concrete plans for a hydrogen pipeline grid already exist, as the so called “European Hydrogen backbone”. As building a completely new pipeline grid is economically not justifiable, a dual-way strategy of repurposing natural gas (NG) pipelines and newly built pipelines is intended. Long distance pipeline grids require regular maintenance and repairs. For NG pipelines in-service welding is state of the art. Concepts such as hot-tapping (drilling into pressurized pipelines) and “stoppling” (sealing off pipeline sections after installing bypasses or pressure relieves) allow the repair of damaged pipeline sections or the installation of new branches without shutting the pipeline down, which in most cases isn’t possible from an economic standpoint. The EIGA 121/14 guideline already pointed out in 2014 that “A hydrogen hot-tap shall not be considered a rou-tine procedure, […]”. This shows that the determination of the transferability of these repair concepts to hydrogen pipelines is of utmost importance. Due to the degrading effects of hydrogen on mechanical properties, commonly referred to as “hydrogen embrittlement” it is necessary to understand and investigate the occurring effects. In the special case of repair welding on in-service hydrogen pipelines an increased hydrogen uptake due to a large heat input and microstructural changes in the material needs to be considered. Therefore, material degradation must be investigated to determine whether modifications of repair procedures are necessary to ensure a reliable and safe hydrogen transportation via pipelines. For this reason, this paper gives an overview on existing weld repair concepts and its risks and limitations in terms of hydrogen absorption and possible embrittlement effects when transferred to hydrogen pipelines. The complexity lies in a large variety of materials (low alloyed steels), pipeline diameters and corresponding weld-ed joints. The material compatibility of materials in used (repurposed NG-pipelines) and new condition must be investigated. Particularly for repurposed/used pipelines the effect of a pre-matured/corroded inner surface and sometimes insufficient documentation of the material “history” needs to be considered. An overview on ongoing and completed R&D-projects with respect to repair concepts for hydrogen pipelines and hydrogen effects on pipeline materials is given. T2 - 77th IIW Annual Assembly and International Conference, Meeting of Commission II-A "Metallurgy of Weld Metals" CY - Ixia, Rhodes Island, Greece DA - 07.07.2024 KW - Hydrogen KW - Pipeline KW - In-Service Welding PY - 2024 AN - OPUS4-60757 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael A1 - Kannengießer, Thomas T1 - Update on "Call for interested people to contribute to series of comprehensive papers on welding and joining of components for sustainable energy systems" N2 - Based on the initial call in March 2024, an update time-frame is introduced on the working plan for a comprehensive review paper series on joining and welding technologies for the manufacturing of components and parts used in sustainable energy generation, conversion, and transport with focus on hydrogen and wind energy. T2 - 77th IIW Annual Assembly and International Conference, Meeting of Commission II-A CY - Ixia, Rhodes, Greece DA - 07.07.2024 KW - Review paper KW - Research study KW - Hydrogen KW - Joining KW - Welding PY - 2024 AN - OPUS4-60674 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael A1 - Kaiser, Sebastian T1 - Repair welding of pressurized in-service hydrogen pipelines: A review on current challenges and strategies N2 - As energy carrier of the future, green hydrogen can make a decisive contribution to a sustainable energy supply. In Europe concrete plans for a hydrogen pipeline grid already exist, as the so called “European Hydrogen backbone”. As building a completely new pipeline grid is economically not justifiable, a dual-way strategy of repurposing natural gas (NG) pipelines and newly built pipelines is intended. Long distance pipeline grids require regular maintenance and repairs. In that conection, for natural gas (NG) pipelines in-service welding is state of the art. Concepts such as hot-tapping (drilling into pressurized pipelines) and “stoppling” (sealing off pipeline sections after installing bypasses or pressure relieves) allow the repair of damaged pipeline sections or the installation of new branches without shutting the pipeline down. The EIGA 121/14 guideline already pointed out in 2014 that “a hydrogen hot-tap shall not be considered a routine procedure”. This shows that the determination of the transferability of these repair concepts to hydrogen pipelines is of utmost importance. Due to the degrading effects of hydrogen on mechanical proper-ties, commonly referred to as “hydrogen embrittlement” it is necessary to understand and investigate the occurring effects. In the special case of repair welding on in-service hydrogen pipelines an increased hydro-gen uptake due to a large heat input and microstructural changes in the material needs to be considered. For this reason, this paper gives an overview on existing weld repair concepts and its risks and limitations in terms of hydrogen absorption and possible embrittlement effects when transferred to hydrogen pipelines. The complexity lies in a large variety of materials (low alloyed steels), pipeline diameters and corresponding welded joints. The material compatibility of materials in used (repurposed NG-pipelines) and new condition must be investigated. Particularly for repurposed/used pipelines the effect of a pre-matured/corroded inner surface and sometimes insufficient documentation of the material “history” needs to be considered. An overview on ongoing and completed R&D-projects with respect to repair concepts for hydrogen pipelines and hydrogen effects on pipeline materials is given. T2 - 77th IIW Annual Assembly and International Conference, Meeting of Commission XI "Pressure Vessels and Piping" CY - Ixia, Rhodes, Greece DA - 07.07.2024 KW - Hydrogen KW - Repair welding KW - Pipelines KW - Study PY - 2024 AN - OPUS4-60673 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Konert, Florian T1 - Investigation of the resistance of X65 pipeline steel and weld to gaseous hydrogen using the hollow specimen technique N2 - The constantly increasing demand for renewable energy sources lead to the necessity of transporting large amounts of hydrogen. Since pipelines enable a cost-effective way for the distribution of gaseous hydrogen, the interaction of hydrogen and the pipeline materials must be carefully investigated as hydrogen can cause a degradation of the mechanical properties under certain conditions. Especially welds, which are assumed to be more susceptible to the degradation enhanced by hydrogen, are of great interest. The aim of this study is to investigate the effect of gaseous hydrogen on the mechanical properties of an X65 pipeline, and the longitudinal submerged arc welding (SAW) welded joint. The tests are conducted using the hollow specimen technique on two types of specimens: one extracted from the base material (BM) and the other extracted as a cross-weld (CW) specimen consisting of base material and weld seam. The specimens are charged in-situ under a pressure of 60 bar and tested using slow strain rate (SSR) tensile tests with a nominal strain rate of 10-5 s-1. The performed tests showed a decrease of the reduction of area (RA) from 72% in inert atmosphere to 52% in hydrogen atmosphere for the CW-specimen and a decrease from 73% in inert atmosphere to 51% for the BM. Metallographic analyses showed the crack initiation between fine grain heat affected zone (FGHAZ) and BM for the specimens tested in hydrogen atmosphere as well as for the reference specimens. This leads to the conclusion that the location of the crack initiation does not change due to the presence of gaseous hydrogen. T2 - 77th IIW Annual Assembly and International Conference 2024 CY - Rhodes, Greece DA - 07.07.2024 KW - Hydrogen KW - Hollow-specimen KW - Pipeline steel KW - SSRT KW - Hydrogen embrittlement PY - 2024 AN - OPUS4-60617 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bernardy, Christopher T1 - Investigation of the thermal radiation from hydrogen jet flames N2 - For industrial applications dealing with hydrogen, the definition of safety distances and the assessment of possible hazards emanating from releases is mandatory. Since hydrogen is usually stored and transported under pressure, one scenario to be considered is the momentum driven release of hydrogen from a leakage with subsequent ignition. In this scenario, the emitted heat radiation from the resulting jet flame to the surroundings has to be determined to define adequate safety distances. For hydrocarbon flames, different jet flame models are available to assess the hazards resulting from an ignited jet release. Since hydrogen flames differ from hydrocarbon flames in their combustion behavior, it has to be checked if these models are also applicable for hydrogen. To evaluate the accuracy of these models for hydrogen jet flames, tests at real-scale are carried out at the BAM Test Site for Technical Safety (BAM-TTS). Herein, the flame geometry and the heat radiation at defined locations in the surroundings are recorded for varying release parameters such as leakage diameter (currently up to 30 mm), release pressure (currently up to max. 250 bar) and mass flow (up to max. 0.5 kg/s). The challenge here is the characterization of the flame geometry in an open environment and its impact on the thermal radiation. Existing heat radiation data from the literature are mostly based on unsteady outflow conditions. For a better comparability with the steady state jet flame models, the experiments presented here are focused on ensuring a constant mass flow over the release duration to obtain a (quasi) stationary jet flame. In addition, stationary outflow tests with hydrocarbons (methane) were also carried out, which are intended to serve as reference tests for checking flame models based on hydrocarbon data. T2 - 15th International Symposium on Hazards, Prevention and Mitigation of Industrial Explosions (ISHPMIE) CY - Naples, Italy DA - 10.06.2024 KW - Hydrogen KW - Release KW - Jet flame KW - Thermal radiation PY - 2024 AN - OPUS4-60512 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Naster, Maximilian T1 - Hydrogen Fire Testing N2 - In this presentation we present a new hydrogen-based test rig for an ongoing feasibility study of using hydrogen as an energy source for the thermal testing of transport packages containing radioactive materials. The test rig will be capable of combusting hydrogen for a wide range of different burner geometries, mass flows and if necessary hydrogen blends. As this type of fire test according to the IAEA boundary conditions does not yet exist, a large number of preliminary investigations, safety assessments and calculations must be carried out in order to develop a viable concept for hydrogen fires. In the first step of the feasibility study, the temperature, structure, and radiation of various hydrogen flames are surveyed. In future works, the results will make it possible to design burner frames that are suitable for fire reference tests in order to make comparisons with pool and propane fires used in assessment procedures today. In parallel comparative numerical simulations are conducted to model the thermal behaviour of hydrogen flames using the software package Ansys®. On the one hand, the numerical simulations support the experiments by providing an overview of numerous parameters and the measuring range; on the other hand, they will help with the design of the burner frame in future work. This paper gives an overview in the design and capabilities of the test rig. Furthermore, the results of the parameter studies show that burner geometry and mass flow provide a significant design margin for the thermal shape of the hydrogen flames. In addition, the results of the initial numerical calculations will be used to determine the necessary sensors, the positions, and their operating range. Only the optimal interaction allows a controlled system that permits user-defined hydrogen fires. T2 - Technical Exchange IRSN – BAM Transport & Storage of Packages for Radioactive Material CY - Berlin, Germany DA - 04.06.2024 KW - Hydrogen PY - 2024 AN - OPUS4-60341 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Gleim, Tobias T1 - Potential Effects of Battery and Hydrogen Fires regarding Regulatory Requirements N2 - Introduction and Necessity of the Investigation The IAEA regulations for the safe transport of radioactive material (IAEA SSR-6) define the safety requirements for different package types and consider different transport conditions. The accident conditions of transport specify different mechanical and thermal tests based on investigations of real accident scenarios. Considering the rapid development of new boundary conditions of transport such as electric mobility and the use of hydrogen as energy source for trucks and other kind of vehicles, potential effects of battery and hydrogen fires in transport accidents should be investigated. The aim is to evaluate the existing test requirements developed and derived decades ago, whether they are covering the current transport situation. This concept paper will briefly present the reasons for detailed investigations as bases for a coordinated research project under the roof of the IAEA. T2 - Technical Exchange IRSN – BAM Transport & Storage of Packages for Radioactive Material CY - Berlin, Germany DA - 04.06.2024 KW - Fire KW - Battery KW - Hydrogen KW - IAEA Regulations PY - 2024 AN - OPUS4-60338 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Erxleben, Kjell T1 - Challenges in repair welding of in-service h2-pipelines N2 - Hydrogen will be one of the most important energy carriers of tomorrow. For the necessary large-scale and long-distance transportation, a reliable pipeline infrastructure is required. It is meanwhile in the most countries accepted to follow a two-way strategy by (I) repurposing the existing natural gas (NG) grid combined with (II) the installation of new pipelines. For example, in Europe a so-called European Hydrogen Backbone (EHB) is planned for 2040. Currently, 28 countries work together to establish a hydrogen pipeline grid of several thousands of kilometers. In that connection, a wide number of materials are used with different thicknesses, strength levels, chemical composition, surface conditions and so on. Worldwide research projects suggest the general compatibility of the currently applied pipeline steels e.g., in Germany the “SysWestH2” project. Nonetheless, the hydrogen gas grid will require regular inspections, repair, and maintenance. In addition, sometimes pipeline tees are required to connect new grids or pipelines the existing infrastructure. From that point of view, existing concepts from NG-grids must be investigated in terms of the transferability to hydrogen service. An overview on occurring challenges for this hydrogen transition, especially for in-service weld repair procedures is given in this presentation. T2 - AMPP 2024 - The Association for Materials Protection and Performance CY - Genoa, Italy DA - 09.06.2024 KW - In-service KW - Pipeline KW - Repair welding KW - High-pressure KW - Hydrogen PY - 2024 AN - OPUS4-60327 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Karapanagiotis, Christos T1 - Towards predictive maintenance of hydrogen pressure vessels based on multi-sensor data fusion and digital twin modeling N2 - Hydrogen pressure vessels are among the most essential components for reliable hydrogen technology. Under current regulations, a mostly conservative strategy is employed, restricting the usage time of hydrogen pressure vessels without providing information on the real remaining lifetime. During the service life, pressure vessels are inspected periodically. However, no established method that can provide continuous monitoring or information on the remaining safe service life of the vessel. In this paper, we propose a sensor network for Structural Health Monitoring (SHM) of hydrogen pressure vessels where data from all sensors are collected and centrally evaluated. Specifically, we integrate three different SHM sensing technologies namely Guided Wave ultrasonics (GW), Acoustic Emission testing (AT), and distributed Fiber Optic Sensing (FOS). This integrated approach offers significantly more information and could therefore enable a transition from costly and time-consuming periodic inspections to more efficient and modern predictive maintenance strategies, including Artificial Intelligence (AI)-based evaluation. This does not only have a positive effect on the operational costs but enhances safety through early identification of critical conditions in the overall system in real-time. We demonstrate an experimental set-up of a lifetime test where a Type IV Composite Overwrapped Pressure Vessel (COPV) is investigated under cyclic loading instrumented with AT, FOS, and GW methods. We acquired data from the sensor network until the pressure vessel failed due to material degradation. The data collected using the three different SHM sensor technologies is planned to be evaluated individually, using data fusion, and AI. In the future, we aim to integrate the measurement setup into a hydrogen refueling station with the data stream implemented into a digital signal processing chain and a digital twin. T2 - 11th European Workshop on Structural Health Monitoring CY - Potsdam, Germany DA - 10.06.2024 KW - Hydrogen KW - Ultrasonic guided waves KW - Fiber optic sensors KW - Acoustic emission KW - Machine learning KW - Pressure vessels KW - Structural health monitoring PY - 2024 AN - OPUS4-60277 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Karapanagiotis, Christos T1 - Structural health monitoring of hydrogen pressure vessels using distributed fiber optic sensing N2 - We report on distributed fiber optic sensing-based monitoring of hydrogen composite overwrapped pressure vessels (COPV) to simultaneously increase the operational lifespan and mitigate maintenance costs. Our approach represents, to the best of our knowledge, the first application of distributed fiber optic sensing for COPV Type IV monitoring, where the sensing fibers are attached to the surface, rather than integrated into the composite material. Specifically, we attach an optical fiber of 50 m to the pressure vessel's surface, covering both the cylindrical and dome sections. We note that our fiber optic sensing technique relies on swept wavelength interferometry providing strain information along the entire length of the optical fiber with high spatial resolution even at the millimeter scale. When the vessel is pressurized, the sensing optical fiber shows a linear strain response to pressure at every position along the fiber. After thousands of load cycles, the vessel finally fails with the optical fiber detecting and precisely localizing the damage in the vessel’s blind dome area. Furthermore, we discuss the potential of state-of-the-art signal processing methods and machine learning for advancing predictive maintenance. This could reduce the number of regular inspections, mitigate premature maintenance costs, and simultaneously increase the vessel’s remaining safe service life. We believe that the structural health monitoring of hydrogen pressure vessels with fiber optic sensors can enhance trust in hydrogen technology contributing to the energy transition in the future. T2 - 11th European Workshop on Structural Health Monitoring CY - Potsdam, Germany DA - 10.06.2024 KW - Hydrogen KW - Composites KW - Pressure vessels KW - Fiber optic sensors KW - Machine learning KW - Structural health monitoring PY - 2024 AN - OPUS4-60275 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bernardy, Christopher T1 - Thermal Radiation Investigations of Real-Scale Hydrogen Jet Flames at High Pressure N2 - In order to reduce global warming, the use of hydrogen as a renewable energy source is becoming more important. To enable this transition, unprecedently large amounts of hydrogen need to be safely transported and stored. Since hydrogen is usually stored and transported under pressure, one scenario to be considered is the release of hydrogen from a leakage with subsequent ignition. The resulting jet flame must be characterized with respect to the thermal radiation emitted into the environment to define safety distances. Various models that characterize the resulting flame shape and radiation already exist in the literature, but these are mainly based on empirical data from hydrocarbon jet flames. To verify the applicability of these models to hydrogen, real-scale tests are carried out at the BAM Test Site for Technical Safety (BAM-TTS) with the aim to assess the flame geometry and the emitted thermal radiation. Parameters such as leakage diameter (currently up to 30 mm), pressure (currently up to max. 250 bar) and mass flow (up to max. 0.5 kg/s) are varied. In particular, the focus will be laid on the measurement and modelling of the thermal radiation. The challenge here is the characterization of the flame geometry in an open environment and its impact on the thermal radiation. Existing heat radiation data from literature are mostly based on unsteady outflow conditions. The experimental setup used here allows for the generation of a steady-state outflow for several minutes and thus a direct comparability with existing (steady-state) models. Furthermore, stationary outflow tests with hydrocarbons (methane) were also carried out, which are intended to serve as reference tests for checking flame models based on hydrocarbon data. Following from the experimental investigations, modelling parameters such as the Surface Emissive Power (SEP) and the radiant heat fraction for hydrogen and methane will be compared to literature data. T2 - Center for Hydrogen Safety Americas Conference, American Institute of Chemical Engineers CY - Las Vegas, NV, USA DA - 21.05.2024 KW - Thermal radiation KW - Hydrogen KW - Release KW - Jet flame PY - 2024 AN - OPUS4-60195 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Konert, Florian T1 - Deep Dive: Visualizing hydrogen assisted cracks in hollow specimens utilizing µCT N2 - The Deep-Dive provides a short introduction and summary of the performed tests on API X65 Pipelinesteels. The aim of the tests is the visualization of hydrogen assisted crack popagation in hollow specimens. T2 - DAAD Green Hydrogen Workshop CY - Online meeting DA - 07.05.2024 KW - Hydrogen KW - Hollow specimen technique KW - µCT KW - Hydrogen embrittlement KW - Pipeline steel PY - 2024 AN - OPUS4-60001 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Processing and application properties of multiple principal element alloys (MPEA) N2 - The presentation gives an overview of BAM's activities on processing influences and application properties of MPEAs in the form of joined and machined high and medium entropy alloys (CoCrFeMnNi and CoCrNi). In the case of welding, the focus is on defect-free welded joints with sufficient mechanical properties. In the case of machining, the focus is on the possible influence on the surface quality of the materials through adequate milling parameters. In addition, the hydrogen absorption and diffusion properties as well as the electrochemical corrosion behavior are fundamentally examined. T2 - FAU-Department Werkstoffwissenschaften, Seminar: Aktuelle Probleme der Werkstoffwissenschaften CY - Erlangen, Germany DA - 25.04.2024 KW - Welding KW - Application properties KW - Machining KW - High-entropy alloy KW - Hydrogen PY - 2024 AN - OPUS4-59975 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bernardy, Christopher T1 - Real scale safety investigations of hydrogen jet flames at high pressure N2 - In order to reduce the human footprint of CO2 emissions and limit global warming effects hydrogen combustion is becoming increasingly important. To enable fuel cells and gas turbines to operates this carbon free fuel, unprecedently large amounts of hydrogen need to be produced and safely transported and stored. The investigation of the effects of accidents involving hydrogen is therefore becoming of outmost importance. Since hydrogen is usually stored and transported under pressure, one scenario to be considered is the release of hydrogen from a leakage with subsequent ignition. The resulting jet flame must be characterized with respect to the thermal radiation emitted into the environment to define safety regulations. Various models that characterize the resulting flame shape and radiation already exist in the literature, but these are mainly based on empirical data from hydrocarbon jet flames.[1-4] To verify these models, a H2 Jet Flame project conducted at BAM, is investigating the safety of momentum driven hydrogen jet flames. For this purpose, large-scale tests are carried out at the Test Site Technical Safety (BAM-TTS). The object of the investigations is to assess the effects of real scale release scenarios regarding flame geometry and the thermal radiation emitted. Parameters such as release angle, leakage diameter (currently 1 mm to 10 mm), pressure (currently up to max. 250 bar) and mass flow (up to max. 0.5 kg/s) are varied. In addition, influences such as the type of ignition, ignition location as well as delayed ignition can also be investigated. The gained knowledge will be compared with existing jet flame models, to validate these and identify a possible need for further development. In particular, the focus will be laid on the thermal radiation of hydrogen flames. The challenge here is the visualization and characterization of the flame geometry in an open environment. Visualization is performed using infrared (IR) camera systems from at least two viewing angles. Measurements of the heat radiation of jet flames, which can be found in the literature, are mostly based on unsteady outflow conditions.The experimental setup used here allows for the generation of a steady-state outflow for several minutes and thus a direct comparability with existing (steady-state) models. Furthermore, the tests can be carried out for comparative measurements with hydrocarbons (methane, etc.) as well as mixtures of hydrogen and hydrocarbons. T2 - European PhD Hydrogen Conference 2024 (EPHyC2024) CY - Gent, Belgium DA - 20.03.2024 KW - Hydrogen KW - Release KW - Jet flame KW - Thermal radiation PY - 2024 AN - OPUS4-59908 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Günzel, Stephan T1 - Safety assessment of hydrogen gas storage systems N2 - In this lecture, the safety assessment of hydrogen gas storage systems is presented using the example of composite pressure vessels. The main element is a probabilistic approval approach based on five steps. Firstly, the testing and evaluation of properties at the beginning of life are shown. Secondly, methods for artificial aging and the effect on the residual strength are presented. Thirdly, testing against dedicated accidents is introduced. Fourthly, effects on the surveillance of production quality are discussed. Finally, degradation and the end of life are estimated. Background information and examples are given for each step. The assessment presented is a method applicable for many safety-related systems. T2 - Joint European Summer School 2021 on Fuel Cell, Electrolyser, and Battery Technologies CY - Online meeting DA - 12.09.2021 KW - Safety KW - Hydrogen KW - Wasserstoff KW - Bewertung KW - Assessment PY - 2021 AN - OPUS4-59905 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Günzel, Stephan T1 - Safety assessment of hydrogen gas storage systems N2 - In this lecture, the safety assessment of hydrogen gas storage systems is presented using the example of composite pressure vessels. The main element is a probabilistic approval approach based on five steps. Firstly, the testing and evaluation of properties at the beginning of life are shown. Secondly, methods for artificial aging and the effect on the residual strength are presented. Thirdly, testing against dedicated accidents is introduced. Fourthly, effects on the surveillance of production quality are discussed. Finally, degradation and the end of life are estimated. Background information and examples are given for each step. The assessment presented is a method applicable for many safety-related systems. T2 - Joint European Summer School 2022, Hydrogen Safety CY - Athens, Greece DA - 18.09.2022 KW - Safety KW - Hydrogen KW - Wasserstoff KW - Bewertung KW - Assessment PY - 2022 AN - OPUS4-59904 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Günzel, Stephan T1 - Safety assessment of hydrogen gas storage systems N2 - In this lecture, the safety assessment of hydrogen gas storage systems is presented using the example of composite pressure vessels. The main element is a probabilistic approval approach based on five steps. Firstly, the testing and evaluation of properties at the beginning of life are shown. Secondly, methods for artificial aging and the effect on the residual strength are presented. Thirdly, testing against dedicated accidents is introduced. Fourthly, effects on the surveillance of production quality are discussed. Finally, degradation and the end of life are estimated. Background information and examples are given for each step. The assessment presented is a method applicable for many safety-related systems. T2 - Joint European Summer School 2023, Hydrogen Safety CY - Online meeting DA - 17.09.2023 KW - Safety KW - Hydrogen KW - Wasserstoff KW - Bewertung KW - Assessment PY - 2023 AN - OPUS4-59903 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Günzel, Stephan T1 - Safety assessment of hydrogen gas storage systems N2 - In this lecture, the safety assessment of hydrogen gas storage systems is presented using the example of composite pressure vessels. The main element is a probabilistic approval approach based on five steps. Firstly, the testing and evaluation of properties at the beginning of life are shown. Secondly, methods for artificial aging and the effect on the residual strength are presented. Thirdly, testing against dedicated accidents is introduced. Fourthly, effects on the surveillance of production quality are discussed. Finally, degradation and the end of life are estimated. Background information and examples are given for each step. The assessment presented is a method applicable for many safety-related systems. T2 - Masterstudiengang Wasserstofftechnologie - Modul 8: Safety and Public Acceptance – Sicherheitsaspekte, Akzeptanz und werkstofftechnische Herausforderungen des Wasserstoffs CY - Online meeting DA - 25.08.2023 KW - Safety KW - Hydrogen KW - Wasserstoff KW - Bewertung KW - Assessment PY - 2023 AN - OPUS4-59899 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Günzel, Stephan T1 - Safety aspects of hydrogen transportation N2 - In this presentation safety aspects of hydrogen transportation are discussed. At first, the regulatory background and level of safety are presented. In the second part, the modelling of consequence due to sudden rupture of pressure receptacles is explained. Finally, the results are used to define a limit for consequence to enable an acceptable and safe transport of hydrogen. T2 - 3rd Germany-Korea Hydrogen Conference CY - Berlin, Germany DA - 27.09.2022 KW - Safety KW - Hydrogen KW - Wasserstoff KW - Gefahrgut KW - Consequence PY - 2022 AN - OPUS4-59902 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael A1 - Kannengießer, Thomas T1 - Call for interested people to contribute to series of comprehensive papers on welding and joining of components for sustainable energy systems N2 - Joining and welding technologies are of high importance for the manufacturing of components and parts used in sustainable energy generation, conversion, and transport. In that connection, offshore and on-shore installed wind turbines are of high interest for the generation of electrical energy as well as photo-voltaic systems (solar cells). The electricity can be either directly transported or conversed via power-to-gas e.g., to hydrogen. In that scope, electrolyzer up to MW-range are of interest as well as the conver-sion back to electricity via fuel cells. In addition, hydrogen is a key element of the decarburization of in-dustries as well as the mobility sector encompassing sea, air and land transportation driven by hydrogen or its derivates. Well-known examples cover the direct reduction of iron ore to replace the conventional blast furnace process up to gas turbines or fuel cells for home-end use. All mentioned technologies re-quire reliable components, which are to a high extend dependent on joining and especially welding pro-cessing of materials. Especially, the (petro-) chemical industry has many years of experience with both materials used in hydrogen applications. The challenge is e.g., the transition to mass production of sys-tem components of electrolyzers/fuel cells and for distribution grids. At this point, the scalability of cur-rently applied joining processes often limits the economic efficiency, whereas especially laser welding or additive manufacturing will be of high interest. In that connection, it is very important to provide answers by joint research of universities, institutes, and industrial companies. Very often, solutions are already available and “just” have to be investigated and adapted for the new application, like repair welding of NG pipelines. For that reason, we want to set up a series of comprehensive papers with the aforementioned title. The idea is to get an in-depth but manageable overview of the importance of joining technologies in sustaina-ble energy generation, conversion, and transport encompassing current processes, limitations, and fur-ther perspectives. In that connection, the additive manufacturing is gaining more and more attention. If applicable, current challenges in the adaption or creation of new standards/regulations shall be addressed. T2 - IIW Intermediate Meeting, Com. II-A CY - Incheon, Republic of Korea DA - 12.03.2024 KW - Hydrogen KW - Welding KW - Comprehensive study KW - Component manufatcturing KW - Additive manufacturing PY - 2024 AN - OPUS4-59676 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Rhode, Michael T1 - Repair welding of pressurized in-service hydrogen pipelines - A review on current challenges and strategies N2 - As energy carrier of the future, green hydrogen can make a decisive contribution to a sustainable energy supply. Particularly important is the decarbonization of heavy industry. Therefore, a reliable supply of hydrogen must be guaranteed. A hydrogen pipeline grid can achieve this purpose. In Europe concrete plans for a hydrogen pipeline grid already exist, as the so called “European Hydrogen backbone”. As building a completely new pipeline grid is economically not justifiable, a dual-way strategy of repurposing natural gas (NG) pipelines and newly built pipelines is intended. Long distance pipeline grids require regular maintenance and repairs. For natural gas (NG) pipelines in-service welding is state of the art. Concepts such as hot-tapping (drilling into pressurized pipelines) and “stoppling” (sealing off pipeline sections after installing bypasses or pressure relieves) allow the repair of damaged pipeline sections or the installation of new branches without shutting the pipeline down, which in most cases isn’t possible from an economic standpoint. The EIGA 121/14 guideline already pointed out in 2014 that “a hydrogen hot-tap shall not be considered a routine procedure”. This shows that the determination of the transferability of these repair concepts to hydrogen pipelines is of utmost importance. Due to the degrading effects of hydrogen on mechanical proper-ties, commonly referred to as “hydrogen embrittlement” it is necessary to understand and investigate the occurring effects. In the special case of repair welding on in-service hydrogen pipelines an increased hydro-gen uptake due to a large heat input and microstructural changes in the material needs to be considered. Therefore, material degradation must be investigated to determine whether modifications of repair procedures are necessary to ensure a reliable and safe hydrogen transportation via pipelines. For this reason, this paper gives an overview on existing weld repair concepts and its risks and limitations in terms of hydrogen absorption and possible embrittlement effects when transferred to hydrogen pipelines. The complexity lies in a large variety of materials (low alloyed steels), pipeline diameters and corresponding welded joints. The material compatibility of materials in used (repurposed NG-pipelines) and new condition must be investigated. Particularly for repurposed/used pipelines the effect of a pre-matured/corroded inner surface and sometimes insufficient documentation of the material “history” needs to be considered. An overview on ongoing and completed R&D-projects with respect to repair concepts for hydrogen pipelines and hydrogen effects on pipeline materials is given. The focus hereby lies on possible methods of material testing and modeling. Its current difficulties, limits and possible solution will be discussed. T2 - IIW Intermediate Meeting, Com. II-A CY - Incheon, Republic of Korea DA - 12.03.2024 KW - Hydrogen KW - Repair welding KW - Pipelines KW - In-service PY - 2024 AN - OPUS4-59674 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Grimault de Freitas, Tomás T1 - State of the Art in the Qualification of Metallic Materials for Hydrogen Technologies N2 - The hydrogen economy is one of the main solutions for achieving climate neutrality in Europe. Metallic materials, predominantly steels, are the most common structural materials in the various components along the hydrogen supply chain. Ensuring their sustainable and safe use in hydrogen technologies is a key factor in the ramp-up of the hydrogen economy. This requires extensive materials qualification, however, most of the accepted, and standardised test methods for determining the influence of gaseous hydrogen on metallic materials describe complex and costly procedures that are only available to a very limited extent worldwide (e.g., autoclave technique). The hollow specimen technique is presented as an alternative method that can overcome the limitations of current techniques and complement them. To standardise the technique, a process has been initiated by ISO in 2021. Knowledge gaps for tests with the technique in hydrogen have been identified by DIN. The H2HohlZug project, which falls under the umbrella of TransHyDE, aims to address the identified knowledge gaps and provide a foundation for a comprehensive standardisation of the hollow specimen technique. T2 - E-World Energy & Water CY - Essen, Germany DA - 20.02.2024 KW - Hydrogen KW - Hydrogen Embrittlement KW - Hollow Specimen Technique KW - High-Pressure Gaseous Hydrogen KW - Standardisation KW - H2HohlZug KW - TransHyDE PY - 2024 AN - OPUS4-59564 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Schulze, Uwe T1 - Measurement of permeation of hydrogen on hoses according to ISO 3821 N2 - The subject of permeation of hoses according to ISO 3821 for hydrogen was discussed for a long time in ISO/TC 44/SC 8. The reason is a considerable leakage of hydrogen diffused into the hose material over the end face of the hose. Because of this unsolved, safety-related problem of hoses sold on the market, measurements should be carried out in order to be able to better assess the problem. BAM has declared its attendance to provide a required fast solution to this issue. T2 - Meeting of the committee ISO/TC 44/SC 8 "Equipment for gas welding, cutting and allied processes" CY - Genoa, Italy DA - 08.11.2023 KW - Permeation KW - Hoses KW - Hydrogen KW - Leakage KW - ISO 3821 PY - 2023 VL - 2023 AN - OPUS4-59375 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Asna Ashari, Parsa T1 - Exploring the Technological Innovation System for Hydrogen Technologies - Four Essays on the Roles of Research, Innovation, and Safety N2 - Presentation of the doctoral thesis held at the PhD Colloquium of the Chair of Innovation Management, Freie Universität Berlin. Hydrogen has recently come into political and industrial focus due to its potential to advance the transition to a net-zero economy. Despite this recognized potential, the market ramp-up of hydrogen technologies has not yet been realized at large. Therefore, this thesis attempts to investigate how advances in hydrogen research, innovation, and safety link up to market formation using the Technological Innovation Systems (TIS) and Quality Infrastructure (QI) frameworks. Thereupon, the thesis formulates several recommendations for transitioning to a hydrogen economy. T2 - PhD Colloquium of the Chair of Innovation Management (Freie Universität Berlin) CY - Berlin, Germany DA - 09.01.2024 KW - Hydrogen KW - Research and innovation KW - Innovation system KW - Safety PY - 2024 AN - OPUS4-59400 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Orellana Pérez, Teresa T1 - Regulations codes and standards for safe hydrogen technologies N2 - Safety in hydrogen technologies in Europe is governed by international and European regulations and standards. An overview on regulatory bodies, technical committees, regulations, directives, standards, and technical guidelines with special attention on the BAM-GGR 021 is given in this lecture. T2 - Joint European Summer School 2023, Hydrogen Safety CY - Athens, Greece DA - 17.09.2023 KW - Hydrogen KW - Safety KW - Regulations KW - Standards PY - 2023 AN - OPUS4-59300 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Orellana Pérez, Teresa T1 - European policy framework for safe hydrogen technologies N2 - This lecture describes the history of hydrogen from the first scientific discoveries in the 18th century to the current technological and political developments for the market ramp-up of hydrogen technologies. The European policy framework for safe hydrogen technologies is explained comprehending the European Green Deal, European Climate Law, European Hydrogen Strategy, Clean Hydrogen Partnership, REPowerEU Plan, Renewable Energy Directive and its Delegated Act, Net Zero Industry Act, etc. T2 - Joint European Summer School 2023, Hydrogen Safety CY - Athens, Greece DA - 17.09.2023 KW - Hydrogen KW - Safety KW - Policies PY - 2023 AN - OPUS4-59297 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Orellana Pérez, Teresa T1 - Guest lecture: European policy framework regulations codes and standards for safe hydrogen technologies N2 - This lecture describes the history of hydrogen from the first scientific discoveries in the 18th century to the current technological and political developments for the market ramp-up of hydrogen technologies. The European policy framework for safe hydrogen technologies is explained comprehending the European Green Deal, European Climate Law, European Hydrogen Strategy, Clean Hydrogen Partnership, etc. Safety in hydrogen technologies is governed by international and European regulations and standards. An overview on regulatory bodies, technical committees, regulations, directives, standards, and technical guidelines with special attention on the BAM-GGR 021 is given in this lecture. T2 - MSc Fuel Cells and Hydrogen Technologies at the University of Birmingham (LM Hydrogen Safety, MSc FCHT module C7B) CY - Birmingham, UK DA - 21.10.2022 KW - Hydrogen KW - Safety KW - Regulations KW - Standards PY - 2022 AN - OPUS4-59296 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Orellana Pérez, Teresa T1 - European policy framework regulations codes and standards for safe hydrogen technologies N2 - This lecture describes the history of hydrogen from the first scientific discoveries in the 18th century to the current technological and political developments for the market ramp-up of hydrogen technologies. The European policy framework for safe hydrogen technologies is explained comprehending the European Green Deal, European Climate Law, European Hydrogen Strategy, Clean Hydrogen Partnership, etc. Safety in hydrogen technologies is governed by international and European regulations and standards. An overview on regulatory bodies, technical committees, regulations, directives, standards, and technical guidelines with special attention on the BAM-GGR 021 is given in this lecture. T2 - Joint European Summer School 2022, Hydrogen Safety CY - Athens, Greece DA - 18.09.2022 KW - Hydrogen KW - Safety KW - Regulations KW - Standards PY - 2022 AN - OPUS4-59295 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Tiebe, Carlo T1 - Hydrogen sensing - Sensors for safety and process control in Hydrogentechnologies N2 - The success of this energy transition and the efficient utilization of green hydrogen as a pristine energy carrier hinge upon the cultivation of hydrogen readiness, swift market expansion, and the establishment of crucial value chains within national and European contexts. Paramount to these objectives are reliable quality and safety standards, essential for ensuring supply safety, environmental compatibility, and instilling confidence in these technologies. In the realm of safety management systems, gas sensors emerge as vital components for detecting hydrogen. This presentation delves into the imperative role of hydrogen systems, emphasizing their capability to monitor and control operations, issue warnings, signal hazardous conditions, and sound alarms. It explores the intricate landscape of functional safety considerations and addresses the challenges associated with measurement uncertainty in sensor testing. A diverse array of sensors catering to hydrogen, pressure, temperature, and flow are available, each contributing significantly to the safety and efficiency of hydrogen technologies. Applications are envisaged to adhere meticulously to quality infrastructural regulations, codes, and standards, ensuring seamless integration and operation within the broader hydrogen ecosystem. This discussion underscores the ubiquitous presence of sensor systems across various fields within hydrogen technologies, illustrating their multifaceted contributions to safety, reliability, and overall success in realizing the transformative potential of green hydrogen. T2 - Summer School 2023 Characterization of micro- and nano-materials at BTU Cottbus CY - Cottbus, Germany DA - 11.09.2023 KW - H2Safety@BAM KW - Hydrogen KW - Sensor KW - Gas detection KW - Process control KW - Safety KW - Sensor testing PY - 2023 AN - OPUS4-59227 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Tiebe, Carlo T1 - Hydrogen sensing - Sensors for safety and process control in Hydrogentechnologies N2 - The success of this energy transition and the efficient utilization of green hydrogen as a pristine energy carrier hinge upon the cultivation of hydrogen readiness, swift market expansion, and the establishment of crucial value chains within national and European contexts. Paramount to these objectives are reliable quality and safety standards, essential for ensuring supply safety, environmental compatibility, and instilling confidence in these technologies. In the realm of safety management systems, gas sensors emerge as vital components for detecting hydrogen. This presentation delves into the imperative role of hydrogen systems, emphasizing their capability to monitor and control operations, issue warnings, signal hazardous conditions, and sound alarms. It explores the intricate landscape of functional safety considerations and addresses the challenges associated with measurement uncertainty in sensor testing. A diverse array of sensors catering to hydrogen, pressure, temperature, and flow are available, each contributing significantly to the safety and efficiency of hydrogen technologies. Applications are envisaged to adhere meticulously to quality infrastructural regulations, codes, and standards, ensuring seamless integration and operation within the broader hydrogen ecosystem. This discussion underscores the ubiquitous presence of sensor systems across various fields within hydrogen technologies, illustrating their multifaceted contributions to safety, reliability, and overall success in realizing the transformative potential of green hydrogen. T2 - Joint European Summer School 2023 on Fuel Cell, Electrolyser, and Battery Technologies CY - Vravrona, Greece DA - 17.09.2023 KW - H2Safety@BAM KW - SensRef KW - Hydrogen KW - KICstartH2 KW - Gas detection KW - Sensor testing KW - Hydrogen gas sensor PY - 2023 AN - OPUS4-59228 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -