Figure 3 . Valve designed for high-pressure hydrogen environments π www . valve-world . net Valve World December 2024 57
Additive Manufacturing
Aspect |
Additive manufacturing ( AM ) |
Traditional manufacturing |
Material innovation |
Allows use of advanced alloys ( e . g ., nickel , titanium ) |
Limited to conventional materials ( e . g ., stainless steel , carbon ) |
Resistance to embrittlement
Design flexibility
Leakage prevention
Up to 40 % greater resistance due to controlled microstructures
High , enabling complex geometries and internal structures
Enhanced through optimised design and precision manufacturing
Prone to hydrogen embrittlement , especially in highpressure environments
Limited , often requires compromises in design due to manufacturing constraints
Higher risk of leakage due to less precise manufacturing processes
Customisation potential |
High , with rapid prototyping and testing |
Limited , changes are costly and time-consuming |
Weight reduction |
Significant reduction through lattice structures and material efficiency |
Standard weight , with limited optimisation opportunities |
Production time |
Faster , particularly for small batches and prototypes , with a 35 % reduction in lead time |
Slower , particularly for custom designs or small batches |
Cost efficiency |
Higher for complex , customised designs ; lower for large-scale production |
Lower for mass production ; higher for customised designs |
Environmental impact |
Reduced material waste and energy consumption by up to 30 % |
Higher material waste and energy consumption |
Thermal performance |
Improved , with the ability to design for specific thermal environments |
Limited by the material properties and design capabilities |
Fatigue resistance |
Enhanced due to the ability to control microstructure and optimise material properties |
Lower , especially in high-pressure , cyclic environments |
development time by 40 %, which accelerates innovation in valve technology ( Johnston & Franklin , 2022 ). This ability to quickly iterate and test designs is crucial in an industry where minimising downtime and ensuring reliability are top priorities .
Overcoming hydrogen embrittlement
Hydrogen embrittlement is a significant challenge in hydrogen valve design , particularly for materials traditionally used in high-pressure applications . Additive manufacturing addresses this issue by enabling the use of materials specifically engineered to resist embrittlement . For instance , AM allows for the precise control of microstructures within the material , enhancing its resistance to crack propagation and other forms of mechanical failure ( Blume & Williams , 2024 ). In a comparative study , AM-produced valves using a titanium-aluminum alloy showed a 35 % improvement in resistance to hydrogen embrittlement compared to traditional steel valves ( Chen & Zhao , 2023 ). This enhancement is particularly important for ensuring the long-term reliability of valves in hydrogen storage and transport systems , where even minor material failures can lead to significant safety risks and financial losses .
Comparative analysis of additive manufacturing vs . traditional manufacturing
To highlight the advantages of additive manufacturing in hydrogen valve design , a comparative analysis with traditional manufacturing methods is essential . The table below summarises key aspects of this comparison .
Statistical analysis and industry impact
The integration of additive manufacturing into hydrogen valve production has led to measurable improvements in key performance indicators ( KPIs ). A study comparing AM-produced hydrogen valves with traditionally manufactured valves found the following :
• Leakage rate : AM-produced valves demonstrated a leakage rate of less than 0.05 %, compared to 0.5 % for traditionally manufactured valves under the same
Figure 2 . Tailored valve structures optimised for hydrogen applications
Figure 3 . Valve designed for high-pressure hydrogen environments π www . valve-world . net Valve World December 2024 57