Hydrogen Embrittlement: What Every OEM Should Know About Fastener Safety

Hydrogen embrittlement is a hidden risk in high-strength fasteners. Left unchecked, it can lead to unexpected failures, expensive downtime, and warranty headaches. At Blue Ribbon Fastener, we take proactive steps to eliminate this risk for our OEM customers, so your assemblies stay safe, compliant, and reliable.
 

What Is Hydrogen Embrittlement?

Hydrogen embrittlement occurs when hydrogen atoms enter the metal lattice of a fastener, typically during manufacturing or surface treatment processes like acid cleaning, pickling, or electroplating. High-strength steels (over ~39 HRC or 1000 MPa tensile strength) are especially susceptible. The result? Reduced ductility and sudden breakage under stress — often long after installation.
 
For OEMs producing safety-critical or high-performance equipment, this isn’t just a quality issue. It’s a risk to your reputation and bottom line.
 

Where the Risk Comes From

• Surface treatments like electroplating, phosphate coatings, or acid pickling introduce hydrogen.
• Welding and heat-treating can also contribute.
• Environmental exposure (corrosion, galvanic reactions) may generate hydrogen post-installation.

 

Steps to Prevent Hydrogen Embrittlement

Bake After Plating
Arguably the most important step in preventing hydrogen embrittlement is to bake your parts. If electroplating is necessary, immediate post-process baking (typically at 190–230 °C for several hours) helps drive hydrogen out of the steel before it can cause damage. This is also called “baking for de-embrittlement” and is a widely accepted mitigation step.
 
Select the Right Material
Use lower-strength steels if the application allows. Fasteners under 1000 MPa tensile strength are much less prone to embrittlement. If high strength is needed, opt for coatings that don’t involve hydrogen-charging processes.
 
Use Low-Hydrogen Surface Treatments
Consider alternatives to traditional electroplating, such as:

• Mechanical plating
• Zinc-aluminum flake coatings
• Hot-dip galvanizing (if application and tolerances allow)

 
Specify Proper Standards
Reference ASTM, ISO, or SAE standards (like ASTM B850 for post-coating baking) in your purchase orders. This ensures your suppliers and platers know you require embrittlement prevention steps.
 
Control Cleaning Processes
Avoid overly aggressive acid pickling on high-strength fasteners. Alkaline cleaning or less aggressive descaling methods can reduce hydrogen absorption.
 
Store and Handle Correctly
Once plated and baked, store fasteners in a dry environment to minimize corrosion, which can generate hydrogen over time.
 
 

BRF: Your Partner in Quality & Reliability

Preventing hydrogen embrittlement isn’t just about compliance; it’s about protecting your reputation. By sourcing your fasteners from Blue Ribbon Fastener, you gain:

• Reduced risk of costly failures or recalls
• Assurance that every lot meets industry standards
• Guidance from a team who understands the unique demands of OEM production

 

Let’s Talk About Your Next Project

Whether you need advice on coating alternatives, documentation for critical applications, or simply peace of mind that your fasteners will perform, we’re here to help. Contact our team to learn how we can support your next production run.