Numerical analysis of hydrogen‐induced blister crack effect on rubber O‐ring dynamic sealing performance

Rubber sealing components are essential for maintaining high‐pressure hydrogen systems. Nonetheless, they are prone to hydrogen‐induced blister cracks under high‐pressure hydrogen environments, which exacerbate the deterioration of rubber properties. In this study, a dynamic finite element model for nitrile butadiene rubber (NBR) seals with hydrogen‐induced blister cracks was developed for high‐pressure hydrogen environments. The effects of various blister crack characteristics (size, number, and spacing), service condition parameters (hydrogen pressure and precompression rate), and kinematic parameters (displacement amplitude and friction coefficient) on the dynamic sealing performance of the interfaces of NBR seals were investigated. The findings revealed that O‐rings with blister cracks showed lower peak contact stresses, narrower effective seal contact widths, and higher peak Mises stresses, leading to decreased sealing performance. Larger and more numerous blister cracks worsened stress concentration, increasing the risk of mechanical damage and seal failure. Higher hydrogen pressures diminished the sealing performance, whereas higher precompression rates enhanced it. Variations in displacement amplitude and friction coefficient also affected seal performance, particularly in the presence of blister cracks. These findings offer crucial theoretical foundations and practical insights for optimizing the manufacture and utilization of rubber O‐rings in the high‐pressure hydrogen environment. Highlights A model of a rubber seal with a hydrogen‐induced blister crack is established. The effect of hydrogen‐induced swelling is considered. The influence of blister cracks on sealing performance is investigated. The relationship between sealing performance and critical parameters is evaluated.