The spinning process will lead to changes in the micro-structure and mechanical properties of the materials in different positions of the high-pressure hydrogen storage cylinder, which will show different hydrogen embrittlement resistance in the high-pressure hydrogen environment. In order to fully study the safety of hydrogen storage in large-volume seamless steel cylinders, this chapter associates the influence of the forming process with the deterioration of a high-pressure hydrogen cylinder (≥100 MPa). The anti-hydrogen embrittlement of SA-372 grade J steel at different locations of the formed cylinders was studied experimentally in three cylinders. The hydrogen embrittlement experiments were carried out according to method A of ISO 11114-4:2005. The relationship between tensile strength, microstructure, and hydrogen embrittlement is analyzed, which provides comprehensive and reliable data for the safety of hydrogen storage and transmission.

Elastic–plastic numerical analysis of the spinning process of SA-372 steel is used in high-pressure hydrogen storage to analyze high-pressure hydrogen storage cylinders with high precision and excellent hydrogen embrittlement resistance. The spinning process of SA-372 steel used to form such a cylinder with a pressure of 100 MPa is investigated through elastic–plastic finite element analysis. The variations in the stress, strain, pressure, temperature, and wall thickness during the spinning processes are comprehensively examined, and the optimized processing parameters are determined based on the numerical analysis results. Finally, these optimal parameters are used to conduct actual spin-forming experiments. The numerical results are found to be in excellent agreement with the experimental results, which verifies the feasibility and effectiveness of the proposed elastic–plastic numerical analysis model for the optimization of spinning process parameters. Furthermore, the hydrogen embrittlement test based on ISO 11114-4:2005 method A proves that the cylinder shoulder has a good hydrogen embrittlement resistance.

This study presents a comprehensive computational and experimental investigation of thread fatigue behavior in ultra-high-pressure hydrogen storage vessels. A high-fidelity finite element model, incorporating axisymmetric assumptions and nonlinear material properties, is developed to simulate stress concentration and crack propagation under multiaxial cyclic loading. Crack growth is evaluated using an iterative fracture mechanics approach based on stress intensity factors, with polynomial fitting applied to characterize axial stress distributions. The influence of hydrogen embrittlement is explicitly considered in the fatigue life prediction through threshold-based stress intensity criteria. To validate the computational results, fatigue experiments are conducted on SA-372J steel vessels under controlled high-pressure hydrogen environments. The computational prediction indicated a fatigue life of approximately 613,190 cycles, while experimental results showed no measurable leakage or thread damage after 60,000 cycles, confirming excellent agreement and validating the model’s accuracy. This work establishes a reliable computational framework for predicting the fatigue life of threaded connections, offering valuable design insights to improve the safety and durability of hydrogen storage vessels operating under extreme service conditions.