This article explores the main mechanisms that can generate damage in polymers and polymer-based materials used for hydrogen storage and distribution infrastructures. All of these mechanisms are driven by the permeability process that is enhanced by the operating temperature and pressure conditions. Hydrogen storage and delivery systems typically work under high pressure and a relatively wide range of temperatures, especially during the filling and emptying processes. Therefore, it is of great interest to better understand how this phenomenon can influence the integrity of polymer-based hydrogen infrastructures in order to avoid catastrophic events and to better design/investigate new optimized solutions. The first part of this paper discusses the main storage and delivery solutions for gas and liquid hydrogen. Then, the physics of the permeability is investigated with a focus on the effect of pressure and temperature on the integrity of polymers working in a hydrogen environment. Finally, the main mechanisms that mostly induce damage in polymers operating in a hydrogen environment and that influence their mechanical properties are explored and discussed. Particular focus was placed on the rapid gas decompression and aging phenomena. In addition, some of the limits that still exist for a reliable design of polymer-based storage and delivery systems for hydrogen are pointed out.

The multiaxial fatigue behavior of Ti6Al4V samples, made by selective laser melting (SLM) process, was investigated in this work. Fatigue tests were carried out under three different loading conditions: (i) tensile, (ii) torsion, and (iii) in‐phase axial–torsional. A modified damage model, based on the Sines criterion, is proposed and used to analyze proportional multiaxial fatigue data. Preliminary results showed that the proposed version provides a better prediction with respect to the Sines model. Infrared thermography and digital image correlation were also used to capture both temperature and strain evolutions during fatigue tests. Fatigue results highlighted different failure modes due to surface crack initiation and internal crack initiation, as also demonstrated by scanning electron microscopy of the fracture surface.

Background: The accurate measurement of residual stresses (RS) is crucial for predicting the performance of mechanical components, as RS can significantly impact fatigue life, fracture, corrosion, and wear resistance. Different experimental methods were developed to measure RS, including non-destructive techniques. Among these methods, instrumented nanoindentation has emerged as a promising approach to assess equi- or non-equi-biaxial RS states. This technique analyzes variations in the mechanical response of indentation on a stressed or stress-free component to estimate residual stresses. Previous studies proposed different approaches to establish a relationship between RS and indentation parameters, such as contact area, peak load, mean contact pressure, indentation work, etc. However, the correlation between RS and peak load variation, commonly assumed to be linear, showed limitations, particularly when dealing with compressive RS. Objective: The aim of this work is to develop a hybrid procedure, based on finite element (FEM) simulations and experimental analyses, to measure the equi-biaxial residual stresses. In particular, it is based on the analysis of the nanoindentation peak load variation generated by the presence of residual stresses on a component. Methods: To overcome the limitations of the linear assumption, nanoindentation experiments were combined with finite element analyses (FEA). FEA simulations were used to estimate the correlation between RS and peak load variation, providing a better understanding of the non-linear relationship. A proper experimental setup, consisting in a stress generating jig, was designed and manufactured to perform nanoindentations on a sample, made by aluminium alloy AA 7050 T451, subjected to external mechanical stress with the aim to validate the FEA model. FEA and the digital image correlation (DIC) technique were also used to verify that the induced stress field was the expected one. Results: Obtained results revealed that the proposed method is a valid way to measure residual stresses. In fact, it offers an improved correlation between RS and peak load variation. In addition, by integrating nanoindentation experiments and FEA, a more accurate assessment of RS can be also achieved. Conclusions: This research contributes to the development of a consistent methodology for RS measurement using instrumented nanoindentation.