Study on hydrogen-induced blister fracture of nitrile butadiene rubber seals servicing in high-pressure hydrogen environments

doi:10.11949/0438-1157.20250455

Abstract

Abstract:

Hydrogen-induced blister fracture is a damage phenomenon that occurs inside the rubber during the rapid depressurization of high-pressure hydrogen. A finite element model is established to investigate hydrogen-induced blister fracture in nitrile butadiene rubber (NBR), a commonly used sealing material. The internal damage evolution mechanism of NBR is discussed under complex operational conditions considering both single and cyclic hydrogen exposure. In addition, the effects of various factors on hydrogen-induced blister fracture in NBR, including fillers, hydrogen permeation characteristics, test conditions, and cavity parameters are studied. The results show that the most likely time for blister fracture in NBR is at the end of single hydrogen exposure. Cyclic hydrogen exposure can amplify cavitation damage and increase the risk of blister fracture. The addition of fillers can improve NBR's resistance to hydrogen-induced blister fracture. The increase in hydrogen solubility and the decrease in hydrogen diffusion coefficient can enhance the possibility of blister fracture. Reducing the hydrogen pressure and the depressurization rate can lower the risk of blister fracture. A larger cavity radius, a smaller distance of two cavities, and a larger number of cavities can bring a greater risk of blister fracture.

Key words: hydrogen, rubber seal, blister fracture, composites, numerical simulation

摘要：

氢致鼓泡断裂是高压氢气快速减压过程中橡胶内部发生的一种损伤现象。针对常用的密封件材料丁腈橡胶（nitrile butadiene rubber，NBR），建立NBR氢致鼓泡有限元模型，研究了单次氢暴露和氢循环暴露工况下橡胶内部损伤演化机制，并探究了填料、氢渗透特性、服役工况参数和空穴参量对NBR氢致鼓泡的影响。结果表明，在单次氢暴露中，泄压结束时刻是NBR最有可能发生鼓泡断裂的时间点；氢循环暴露会扩大空穴损伤，加剧鼓泡断裂风险。填料的加入可提高NBR的抗氢致鼓泡断裂。氢溶解度的增大、氢扩散系数的减小会提高鼓泡断裂的可能。减小氢气压力和泄压速率可以降低鼓泡断裂风险。较大的空穴半径、较小的空穴间距以及较大的空穴数量会带来较大的鼓泡断裂风险。

关键词: 氢, 橡胶密封件, 鼓泡断裂, 复合材料, 数值模拟

CLC Number:

TB 42

Chilou ZHOU, Zhiyu LI, Yiran ZHENG. Study on hydrogen-induced blister fracture of nitrile butadiene rubber seals servicing in high-pressure hydrogen environments[J]. CIESC Journal, 2025, 76(10): 5262-5276.

周池楼, 李治宇, 郑益然. 高压氢环境下丁腈橡胶密封件氢致鼓泡断裂研究[J]. 化工学报, 2025, 76(10): 5262-5276.

Figures/Tables 18

Table 1 Material model parameters for NBR

种类	参数
种类	μ₁	μ₂	μ₃	α₁	α₂	α₃
NBR-NF	-1.11867425	0.55769888	2.22428450	3.95182467	4.29235510	-5.95262505
NBR-CB60	-1.03881682	0.04061428	3.42857186	3.25216863	4.47136825	-6.19905068
NBR-SC40	-2.69313709	0.00685580	5.37184092	0.76680401	5.66714773	-3.78859558
NBR-SC60	-12.83982220	0.38383626	15.57560000	-0.81938224	3.49021679	-1.84497194
NBR-SC80	-1.21929769	-5.31274737	15.08764880	-1.99373914	3.35181852	-6.40709787

Fig.1 Schematic diagram of geometry of NBR hydrogen-induced blister

Fig.2 Boundary conditions

Fig.3 Mesh division of different numbers of elements

Fig.4 Normalized maximum principal strain and accuracy error corresponding to the number of elements

Fig.5 Model reliability verification[40]

Fig.6 Mises stress, principal strain, hydrogen concentration, and hydrogen flux across the NBR sample at the end of pressurization

Fig.7 Mises stress, principal strain, hydrogen concentration, and hydrogen flux across the NBR sample at the end of pressure maintenance

Fig.8 Mises stress, principal strain, hydrogen concentration, and hydrogen flux across the NBR sample at the end of depressurization

Fig.9 Mises stress, principal strain, hydrogen concentration, and hydrogen flux across the NBR sample at the end of ambient pressure

Fig.10 Principal strain across the NBR sample with depressurization at (a) 0 s, (b) 375 s, (c) 450 s, (d) 480 s, (e) 510 s, (f) 540 s

Fig.11 External and internal pressure of NBR exposed to 20 hydrogen cycles

Fig.12 Maximum Mises stress, maximum principal strain, maximum hydrogen concentration, maximum hydrogen flux, and maximum displacement of NBR during hydrogen cycle exposure

Fig.13 Effect of hydrogen solubility on cavity damage of three kinds of NBR

Fig.14 Effect of hydrogen diffusion coefficient on cavity damage of three kinds of NBR

Fig.15 Effect of hydrogen pressure on cavity damage of three kinds of NBR

Fig.16 Effect of depressurization rate on cavity damage of three kinds of NBR

Fig.17 Effect of cavity parameters on cavity damage of three kinds of NBR

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