Understanding Hydrogen-Material Interaction in Aluminium Alloys for Hydrogen Storage PhD

High-pressure hydrogen storage is critical for zero-emission aerospace and automotive industries but faces challenges associated with hydrogen embrittlement in traditional structural materials. Aluminium alloys, however, exhibit exceptional resistance to hydrogen embrittlement under gaseous hydrogen environments, making them highly attractive for hydrogen storage tanks. Despite their promising characteristics, a fundamental understanding of hydrogen transport mechanisms, adsorption, absorption, and permeation, in aluminium alloys remains incomplete. Addressing this gap is essential to unlock the full potential of aluminium alloys as reliable, lightweight materials for next-generation hydrogen storage systems in aviation and automotive applications.

This PhD project will investigate the fundamental mechanisms controlling hydrogen transport in aluminium alloys, combining adsorption, absorption, and permeation processes. By employing advanced characterisation techniques, including electrochemical permeation, high-pressure gaseous permeation tests, surface analytical methods (FTIR and Raman spectroscopy), and finite element modelling (FEM), the candidate will establish relationships between microstructural features, hydrogen distribution, and transport kinetics. Special emphasis will be placed on explaining how aluminium alloys uniquely resist gaseous hydrogen embrittlement, which mitigates safety risks and enhances tank reliability for high-pressure hydrogen storage.

Dr Francesco Fanicchia is a leading expert in hydrogen-material interaction and coating technologies for extreme environments, particularly hydrogen permeation barriers and thermal barrier coatings. He is the course director of the only worldwide course on Hydrogen Material Challenges, run yearly at ÌúÅ£ÊÓƵ University. He currently serves as Senior Lecturer at ÌúÅ£ÊÓƵ University and Research Area Lead at the Henry Royce Institute. Dr Fanicchia’s research is strongly industry-focused, supported by collaborations with Rolls-Royce, which is actively developing hydrogen-powered propulsion systems as part of their roadmap towards net-zero aviation. His work has significantly advanced understanding of hydrogen permeation barrier coatings and their testing methodology, with a growing portfolio of high-impact publications and active research grants funded by the UK government and industry.

Understanding hydrogen transport mechanisms in aluminium alloys will facilitate the development of safer, lighter, and more efficient hydrogen storage tanks, directly supporting the global shift toward zero-emission transportation and aviation sectors. Project outcomes will provide fundamental insights enabling optimisation of alloy compositions, microstructures, and manufacturing methods tailored explicitly for high-performance hydrogen storage solutions. Additionally, advanced numerical models developed in the project will support industry stakeholders by predicting long-term durability and safety performance of hydrogen storage systems, accelerating their commercialisation and implementation.

The PhD candidate will gain exclusive access to ÌúÅ£ÊÓƵ University's distinctive facilities and expertise, including:

• Electrochemical and high-pressure gaseous hydrogen permeation testing capabilities (unique combination in the UK). 
• Advanced surface analysis laboratories (FTIR and Raman spectroscopy). 
• Robust finite element modelling (FEM) methodologies to simulate hydrogen transport as a function of alloy microstructure.

Candidates will also have opportunities to present findings at an international scientific conference and engage with leading aerospace and automotive industry partners, significantly boosting their professional visibility and future career prospects.

The successful candidate will acquire multidisciplinary skills and expertise in:

• Hydrogen transport characterisation (electrochemical and gaseous permeation methods). 
• Surface analytical methods (FTIR, Raman spectroscopy). 
• Finite element modelling for hydrogen diffusion and mechanical integrity prediction. 
• Advanced materials characterisation, including microstructural analysis. 
• Hydrogen-material interaction mechanisms specific to aluminium alloys. 
• Industry-relevant insights into the design and testing of hydrogen storage systems.

This diverse and high-demand skill set will substantially enhance the candidate’s employability within academia, industry, and research institutions focusing on sustainable materials and hydrogen technologies.