ETHER rig – high-pressure hydrogen testing for materials and welded joints

TWI is commissioning the ETHER rig (Extreme-Temperature Hydrogen Environment Rig) — a unique facility designed to test materials, welds, and coatings under realistic high-pressure hydrogen conditions. Scheduled to be operational by late 2026, ETHER will provide an essential capability for industries pursuing hydrogen propulsion, energy storage, and refuelling technologies, including space and aerospace applications.

The rig will enable exposure and mechanical testing of materials in gaseous hydrogen at pressures up to 500 bar and temperatures up to 425 °C, allowing direct assessment of hydrogen embrittlement, diffusion, fatigue, and fracture behaviour in relevant service environments.

Key capabilities

• High-pressure operation: gaseous hydrogen testing up to 500 bar.

• High-temperature capability: up to 425 °C continuous exposure.

• Test flexibility: supports welded joints, coated specimens, and bulk materials.

• Measurement instrumentation: real-time pressure, temperature, and strain monitoring.

• Safety systems: fully automated controls, inert purge cycles, and leak detection.

• Custom test configurations: tension, fatigue, or fracture mechanics tests in controlled hydrogen atmospheres.

Applications and relevance

ETHER will support the qualification of materials, welding consumables, and joining processes for hydrogen-rich environments. This includes:

• Hydrogen storage and transport systems for launch and orbital propulsion.

• Re-usable rocket tanks and fuel lines exposed to cyclic pressurisation.

• Ground-based hydrogen infrastructure supporting test and launch operations.

• Fusion and energy systems using hydrogen or deuterium isotopes.

Collaboration invitation

TWI invites industrial and research partners to engage in early collaboration for test method definition, benchmarking, and pre-qualification studies ahead of ETHER’s 2026 launch. The rig will form part of TWI’s wider hydrogen technology platform, complementing expertise in materials testing, fracture mechanics, and joining for extreme environments.