Behavior of Nonmetallic Materials in High-pressure Hydrogen Environment: Chemical Compatibility and Rapid Gas Decompression

Abstract Hydrogen is an essential for the global energy transition, with projections by the International Renewable Energy Agency indicating it could meet 14% of global final energy demand by 2050. As the hydrogen supply chain scales up, the durability of nonmetallic materials, particularly for sealing and containment of equipment such as valves and pipes, becomes critical to ensure asset integrity under high-pressure service conditions. This study investigates the hydrogen compatibility and rapid gas decompression (RGD) resistance of oil/gas qualified specific nonmetallic materials (FFKM, FKM, FEMPM, HNBR, PEEK, PTFE and Nylon). Non-metallic materials were exposed to 100% hydrogen at 100 °C, 120 °C, and 150 °C under 34.5 MPa for 28 days. Post-aging mechanical testing confirmed that all materials passed ISO 23936 acceptance criteria with no significant degradation. RGD testing was conducted at 100 °C and 15 MPa with controlled depressurization (2 MPa/min) over eight cycles. Morphology study were performed to evaluate filler dispersion and its correlation with RGD performance. Chemical and thermal analyses using FT-IR, DSC/TGA showed no significant degradation or change in Tg. These compound specific results support the use of advanced nonmetallic polymers in hydrogen applications, offering confidence in their qualification for emerging hydrogen infrastructure and low-carbon energy systems.