Application of Mechanical Design and Finite Element Analysis in the Evaluation of Hydrogen Embrittlement in Metals. Case study: Development of an adapter for tensile testing of hollow specimens pressurized with hydrogen

Abstract

Hydrogen embrittlement is one of the most complex and critical degradation mechanisms affecting metallic materials used in industrial, energy, and transport applications. The experimental evaluation of this phenomenon has driven the development of mechanical testing methodologies under controlled hydrogen environments, which usually require specialized and costly equipment. In this context, this work presents the design, analysis, and validation of a removable adapter system that enables tensile testing of hollow metal specimens pressurized with hydrogen using a conventional universal testing machine.

The system was developed through an integrated methodology including theoretical analysis, computer-aided design, finite element validation. ASTM 316 stainless steel was selected as the main construction material due to its recognized resistance to hydrogen embrittlement. Initial proposals, iterations based on FEA results (equivalent deformations and von Mises stresses), and the optimized final proposal are described. The results demonstrate that the proposed design meets the required structural and functional conditions for experimental application, providing a replicable solution for mechanical testing in hydrogen environments.

Recommendations for future developments are proposed, aligned with standards like ASTM E8 and HE studies.