# Coupled Multiphysics Numerical Simulation of a Thermo-Elastohydrodynamic O-Ring in a High-Pressure Hydrogen Gas Quick Coupler

## TL;DR

This paper develops a new simulation model to study how high-pressure hydrogen affects seals in quick couplers used in hydrogen refueling stations.

## Contribution

A novel coupled multiphysics model integrating FEM and FVM is introduced to analyze hydrogen flow and seal deformation.

## Key findings

- The model captures nonlinear interactions between hydrogen flow and O-ring deformation.
- The simulation helps improve the design of high-pressure hydrogen couplers for durability and safety.
- Variations in temperature, pressure, and O-ring thickness significantly impact seal performance.

## Abstract

In this study, a novel mechanical fluid–structure interaction (FSI) model is developed to analyze and discuss high-pressure hydrogen flow in a quick coupler under various operating conditions. The transient-state behavior is investigated with respect to different temperatures, hydrogen pressures, and O-ring thicknesses, which directly affect the compression and deformation of the seal. High-pressure hydrogen flow, which may lead to seal damage or failure, is of growing concern due to the increasing use of hydrogen in refueling stations, a sector expected to play a key role in the future of clean energy infrastructure. This study aims to introduce a coupled multiphysics approach by integrating the Finite Element Method (FEM) for solid mechanics with the Finite Volume Method (FVM) for hydrogen flow modeling. The coupling model shows nonlinear interactions between flowing hydrogen and the deformable polymer seal. The results of this work are expected to enhance both the design and performance of high-pressure hydrogen quick couplers, especially for applications in next-generation hydrogen refueling stations, where durability, sealing efficiency and safety are critical.