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<p>The safe and efficient transport of hydrogen gas is essential for advancing a hydrogen-based economy. High-pressure steel pipelines are commonly used for this purpose, but their susceptibility to hydrogen embrittlement (HE) poses a major challenge, often requiring conservative operating conditions. To overcome this, polymer coatings are being explored as a cost-effective and durable alternative to traditional metal and ceramic coatings. In this study, polytetrafluoroethylene (PTFE) and fluorinated ethylene propylene (FEP) were deposited using spin coating to develop free-standing films for hydrogen permeability testing. A total of 12 different approaches were tested to achieve successful delamination of the coatings from various substrates, including the use of sacrificial layers. However, most attempts resulted in coating failure due to issues such as solvent attack, cracking and polymer degradation during curing. As a result, quantitative hydrogen permeability measurements could not be carried out. Among the tested approaches, the ninth method showed partial success in delaminating the PTFE film, though surface cracks were still observed. Scanning electron microscopy (SEM) was used to assess the surface morphology and identify defects. These findings emphasize the need for further optimization in film fabrication techniques to produce robust, defect-free free-standing films for effective use as hydrogen permeation barriers (HPBs). From the authors’ perspective, these initial results provide valuable direction for improving coating strategies and offer a foundation for future development of polymer-based protective layers in hydrogen infrastructure applications.</p>

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Challenges in fabricating free-standing films of polytetrafluoroethylene and fluorinated ethylene propylene polymers for hydrogen barrier applications

  • 期刊论文

  • 发表日期：

    2026年3月24日

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  • Danavath Balu,
  • Piyush Chandra Verma,
  • Prabakaran Saravanan

摘要

The safe and efficient transport of hydrogen gas is essential for advancing a hydrogen-based economy. High-pressure steel pipelines are commonly used for this purpose, but their susceptibility to hydrogen embrittlement (HE) poses a major challenge, often requiring conservative operating conditions. To overcome this, polymer coatings are being explored as a cost-effective and durable alternative to traditional metal and ceramic coatings. In this study, polytetrafluoroethylene (PTFE) and fluorinated ethylene propylene (FEP) were deposited using spin coating to develop free-standing films for hydrogen permeability testing. A total of 12 different approaches were tested to achieve successful delamination of the coatings from various substrates, including the use of sacrificial layers. However, most attempts resulted in coating failure due to issues such as solvent attack, cracking and polymer degradation during curing. As a result, quantitative hydrogen permeability measurements could not be carried out. Among the tested approaches, the ninth method showed partial success in delaminating the PTFE film, though surface cracks were still observed. Scanning electron microscopy (SEM) was used to assess the surface morphology and identify defects. These findings emphasize the need for further optimization in film fabrication techniques to produce robust, defect-free free-standing films for effective use as hydrogen permeation barriers (HPBs). From the authors’ perspective, these initial results provide valuable direction for improving coating strategies and offer a foundation for future development of polymer-based protective layers in hydrogen infrastructure applications.