Qualification and Pre-Screening of Lubricants for Use in High-Pressure Hydrogen Tanks: Ensuring ISO 14687 Grade D Purity Within Fuel Cell Drive Trains

Fuel cell electric vehicles (FCEVs) require specific hydrogen purity, as even trace contaminants can degrade proton exchange membrane fuel cells (PEMFCs). While hydrogen quality is monitored along the supply chain according to international standards, potential contamination from in-vehicle materials, such as lubricants and greases, remains largely unexplored. Here, we present a staged testing framework consisting of (i) a rapid pre-screening for formulation stability and (ii) a full qualification pathway to assess lubricant-derived contamination under realistic refueling conditions. Candidate lubricants were exposed to hydrogen in a 700 bar Type IV vessel following an SAE J2601 refueling procedure. Contamination risks were evaluated by optical inspection, particulate matter, and gas analysis, monitoring contaminants specified in ISO 14687:2025 Grade D. The applicability of the framework was demonstrated in practical scenarios. In the pre-screening pathway, a silicone-based formulation fulfilled the 24 h acceptance criteria for formulation stability and was classified as potentially suitable for high-pressure hydrogen tank applications. In contrast, two other lubricants based on silicone and mineral oil exhibited visible changes associated with increased risk of particulate matter release, resulting in a classification of unsuitable. In the full qualification pathway, the fluorinated DuPontTM MOLYKOTE® HP-300 Grease was evaluated over 23 days and showed no release of harmful contaminants into the hydrogen gas, leading to the classification of suitable. Collectively, the presented protocols provide a structured basis for screening and qualifying lubricants for high-pressure hydrogen tanks in PEMFC applications, supporting future standardization in hydrogen technologies.