Research Status and Prospect of High-strength Steel Hydrogen Resistant Coating

XU Yang; WANG Xiaohe; WANG Yujiang; WEI Shicheng

doi:10.16490/j.cnki.issn.1001-3660.2026.04.001

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Surface Technology ›› 2026, Vol. 55 ›› Issue (4) : 1-17. DOI: 10.16490/j.cnki.issn.1001-3660.2026.04.001

Corrosion and Protection

Research Status and Prospect of High-strength Steel Hydrogen Resistant Coating

XU Yang¹, WANG Xiaohe^2,*, WANG Yujiang², WEI Shicheng²

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Abstract

High-strength steel is widely utilized in aerospace, automotive, and energy engineering due to its exceptional mechanical properties. However, hydrogen embrittlement (HE) poses a significant challenge, limiting its broader application. This paper comprehensively reviews recent advancements in hydrogen barrier coatings for high-strength steel, with focuses on their mechanisms such as surface barrier effects, hydrogen trapping, and diffusion path blocking, and evaluates the performance of various coating materials, including oxides, nitrides, carbon-based materials, and metal alloys.
To address the hydrogen embrittlement issue in high-strength steel, hydrogen barrier coating technology has been developed, which forms a dense protective layer on the surface to prevent hydrogen atoms from migrating into the substrate. With the rapid development of the hydrogen energy industry, the research scope of hydrogen barrier coatings has expanded from the nuclear industry to civilian fields such as hydrogen storage containers, hydrogen transmission pipelines, and fuel cells, establishing a multi-synergistic protective mechanism involving "physical barrier, chemical adsorption, and energy barrier regulation". This technology not only extends the service life of materials but also effectively reduces the cost of replacing expensive components due to hydrogen embrittlement.
Recent research breakthroughs in hydrogen barrier coatings worldwide have led to the development of various coating systems, including oxides, nitrides, carbon-based materials, metal alloys, and multi-layer composite structures. Researchers have conducted systematic investigations into the preparation processes, hydrogen barrier properties, microstructures, and interfacial bonding characteristics of these coatings with high-strength steel substrates. However, the specific mechanisms of the hydrogen barrier effect of coatings have not been fully elucidated, and there remains significant potential for performance optimization.
The hydrogen barrier efficacy of coatings primarily involves three mechanisms, which often work synergistically in advanced designs: surface barrier, hydrogen trapping, and diffusion path blocking. The surface barrier mechanisms rely on dense, defect-free coating microstructures to physically block the adsorption and dissociation of hydrogen at the material surface. The hydrogen trapping mechanism utilizes intentional microstructural defects, such as nanoscale precipitates or lattice distortions, to immobilize diffusing hydrogen atoms, acting as "sinks" that bind hydrogen with sufficient energy to prevent its migration to critical regions of the steel substrate. The diffusion path blocking mechanism is achieved through the strategic engineering of coating architectures, such as multi-layered structures or grain boundary engineering, which significantly extends hydrogen migration routes, slowing down hydrogen permeation to manageable rates.
A variety of coating preparation technologies with distinct advantages and limitations are available. Vapor deposition techniques produce high-purity and uniform films but face challenges in scalability due to high equipment costs and low deposition rates. Thermal spraying enables rapid deposition and is adaptable to complex geometries, yet porosity and weak interfacial adhesion limit long-term performance. Recent innovations, such as post-spray nitriding to form AlN interlayers, have improved hydrogen permeation reduction factors (PRFs) by 100%. Electrochemical deposition is cost-effective for metals, achieving up to 95% hydrogen permeation inhibition, but struggles with ceramic coatings due to issues like porosity and uneven film formation.
Performance evaluation methods for hydrogen barrier coatings, such as electrochemical hydrogen permeation testing using Devanathan-Stachurski cells and gas-phase permeation systems, play a crucial role in quantifying hydrogen fluxes, diffusion coefficients, and trapping efficiency. These methods help assess the effectiveness of coatings in real-world operating conditions.

Key words

high-strength steel / hydrogen embrittlement / hydrogen barrier coating / hydrogen permeation

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XU Yang, WANG Xiaohe, WANG Yujiang, WEI Shicheng. Research Status and Prospect of High-strength Steel Hydrogen Resistant Coating[J]. Surface Technology. 2026, 55(4): 1-17

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