Effect of Hydrogen-Containing Fuel on the Mechanical Properties of an Aluminum Alloy ICE Piston

The transition to cleaner, hydrogen-containing fuels is critical for reducing the environmental impact of marine infrastructure, yet their potential effects on the durability and mechanical reliability of engine components remain a significant engineering challenge. Although aluminum alloys are generally regarded as less susceptible to hydrogen-induced degradation and are widely applied in internal combustion engine components, experimental data obtained under real operating conditions with hydrogen-containing fuel mixtures remain insufficient to fully assess all potential risks. In the present study, two identical low-power gasoline engine–generators were operated for 220 h on fuels with and without hydrogen. Post-test analysis included mechanical testing and microstructural characterization of aluminum alloy pistons for comparative assessment. The measured values of ultimate tensile strength, elongation and deflection, maximum bending force, and effective stress concentration factor revealed pronounced property degradation in the piston operated on the gasoline–hydrogen mixture compared to both the new piston and the one run on pure gasoline. Microstructural analysis provided a plausible explanation for this degradation. The results of this preliminary study provide insights into the effects of hydrogen-containing fuel on the mechanical performance of engine component alloys, contributing to the development of safer and more reliable marine energy systems.