Imperial research targets safer, more durable alloys for clean hydrogen energy

A £859k EPSRC grant will support research to prevent hydrogen embrittlement in metals.

Dr Livia Cupertino-Malheiros, Assistant Professor in Mechanics of Materials in the Department of Civil and Environmental Engineering, will lead the new project ‘Hydrogen Embrittlement Mitigation by Engineering Grain Boundary Composition’ beginning in early 2026. The work will improve the resilience of metals exposed to hydrogen, helping to advance safe, durable infrastructure for the clean energy transition.

Stopping cracks before they start

Hydrogen embrittlement happens when tiny hydrogen atoms slip into weak spots inside metals and make them brittle. These weak spots are called ‘grain boundaries’, the invisible lines where different crystal-like regions of a metal meet. When hydrogen builds up there, the metal can suddenly crack and break.

This hidden process poses risks for critical components used in energy and transportation, where metals must withstand extreme conditions. By identifying the best grain boundary structures to resist hydrogen, the project aims to guide the design of new alloys that can stay strong even in challenging environments.

Lab meets laptop

We hope to provide industry and society with more durable alloys that will support the safe growth of hydrogen as a clean energy source. Dr Livia Cupertino-Malheiros Assistant Professor in Mechanics of Materials

The project will bring together advanced laboratory experiments and computer modelling. Metal alloy samples will be manufactured and examined using powerful microscopes to reveal their internal structures. These samples will then undergo innovative micromechanical and fracture testing to see how they respond to hydrogen.

The experimental results will feed into a new computational model designed to predict hydrogen embrittlement with greater accuracy. By combining small-scale experiments with large-scale simulations, the research will provide a much clearer picture of how metals behave in real-world conditions.

Dr Cupertino-Malheiros said: “This project gives us the chance to unlock a deeper understanding of how metals degrade in the presence of hydrogen. By combining expertise across materials science, engineering and modelling, we hope to provide industry and society with more durable alloys that will support the safe growth of hydrogen as a clean energy source.”

Stronger metals, stronger future

The project will draw on expertise from across Imperial and beyond. Dr Cupertino-Malheiros will collaborate with specialists in metal manufacturing, cryo-microscopy, micromechanical testing, and atomistic and fracture simulations. Together, the team aims to produce both fundamental new knowledge and practical engineering strategies that alloy manufacturers can adopt.

The research could benefit industry by guiding the creation of stronger, longer-lasting metals, especially in the steel and energy sectors. It also aims to support academic communities working in metallurgy and materials science, as well as train the next generation of researchers through a funded PhD student and postdoctoral role. Ultimately, society stands to gain from safer, more robust hydrogen infrastructure, a crucial step towards building a cleaner, more sustainable energy future.