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Green hydrogen (gHâ‚‚) is one of the most promising energy carriers for a climate-neutral future. However, due to hydrogen’s extremely low molecular weight and high diffusivity, its safe storage and transportation remain major materials science challenges. The international HYPOLFAIL consortium — with the involvement of the University of ¾«¶«Ó°Òµ — offers a comprehensive materials development solution to this issue: it is developing innovative polymer-based approaches that reduce hydrogen permeation, prevent embrittlement, and significantly extend the lifespan of components.

The novelty of the project lies not only in its end product but also in its development process. Researchers employ AI-assisted, multiscale modeling — from (sub)molecular levels through finite element (FEM) and thermo-diffusion simulations, all the way to digital twins of the finished components. This synthetic database is enhanced with unsupervised learning, enabling rapid identification of optimal formulations while minimizing the number of time-consuming physical experiments.

This approach allows the elastomers and thermoplastics developed in HYPOLFAIL to achieve ≥10% lower hydrogen permeation and ≥20% longer lifespan compared to current industrial materials. The resulting material portfolio not only supports the EU’s "Fit for 55" climate package but also sets a new industry standard in the global hydrogen technology market.

II. Tasks and Objectives

The HYPOLFAIL project structure is built on three interconnected pillars:

Materials Design and Optimization

• Formulation of hydrogen-compatible elastomers and thermoplastic polymers.

• Fine-tuning chemical composition, morphology, and processing parameters to maximize resistance to permeation and embrittlement.

Multiscale Modeling and Experiments

• Quantum chemical and molecular dynamics simulations to analyze H₂–polymer chain interactions.

• Finite element, thermal, and diffusion models to predict component-level behavior.

• In situ and ex situ high-pressure tests across multiple temperature ranges to calibrate the models.

• Unsupervised learning for automatic simulation parameter optimization and synthetic database creation.

Validation Use Cases

• Elastomer O-ring for high-pressure seals — full component testing under real pressure and thermal profiles, with lifespan estimation.

• Type IV composite tank with thermoplastic liner — a demonstrator validating the modeling process, laying the groundwork for the scientific development of a Type V fully metal-free pressure vessel.

These activities will result in structure–property maps and Bills of Materials (BOMs) for all stages of the hydrogen supply chain, facilitating rapid industrial adoption and future circular material use.

III. The International Project’s Overarching Goals, Objectives, and Expected Outcomes

Overarching Goals:

• Safety – Significantly reduce the risk of hydrogen leakage and embrittlement across the entire storage and transportation infrastructure.

• Cost-effectiveness – Longer maintenance cycles, lower operational costs, and reduced material losses.

• Sustainability – Integration of circular material pathways (design for recycling) from the earliest stages of R&D.

• Global Competitiveness – Strengthen Europe's leadership in key material innovations for the hydrogen economy.

Expected Outcomes:

• Certification of at least two new standardized polymer grades for high-pressure hydrogen applications.

• Industry guideline for selecting and qualifying polymer-based hydrogen components.

• Open-access database of digital twins for hydrogen-compatible polymers for use by researchers and engineers.

• Launch of a technology transfer program for European and international industrial partners.

Together, these outcomes will accelerate the adoption of low-carbon hydrogen, contribute to the EU’s 2050 climate neutrality goals, and lay the foundation for a safe and competitive hydrogen economy.

IV. About the Project

The University of ¾«¶«Ó°Òµ submitted a grant application on 14 February 2025 under the call titled "Support for Hungarian Organizations Successfully Participating in Joint International Calls of ERA-NET COFUND, EJP COFUND and Other Multilateral Programs" (code: 2024-1.2.2-ERA-NET), with the project titled "Polymer Damage Caused by Hydrogen at High Pressure: Understanding Interactions and Failure Mechanisms" (ID: 2024-1.2.2-ERA_NET-2025-00024). According to the decision issued on 2 June 2025, the application was awarded non-refundable support of HUF 59,624,999 from the National Research, Development and Innovation Fund.

The project commenced on 1 May 2025 and will conclude on 30 April 2028. It is being carried out by the University of ¾«¶«Ó°Òµ in consortium with the following partners:
SCIOFLEX Hydrogen GmbH, GDTech s.a., Seal Maker Produktions- und Vertriebs GmbH, University of Liège (Laboratory of Computational & Multiscale Mechanics of Materials), Johannes Kepler University (Institute of Polymer Product Engineering), and Matelios.