Crystallographic control of hydrogen ingress in bcc-Iron: Insights from ab initio simulations

Hydrogen uptake into body-centered cubic (bcc) iron as a root cause for subsequent hydrogen embrittlement, is initiated at the surface. In this paper, we quantify how readily H diffuses from the surface into the bulk. We consider a set of low-index, vicinal and general Fe surfaces and treat H-permeation as a two-step process. First, density-functional calculations determine the adsorption energy of an isolated H atom at every crystallographically distinct surface site. Second, for each adsorption site we map the minimum-energy pathway that carries the atom beneath the surface and into the lattice. Across all ten orientations studied, a clear trend emerges: sites that bind hydrogen most weakly (highest adsorption energy) are the starting point of the lowest-barrier diffusion channels into the metal interior. Thus, the least-favorable adsorption pockets act as gateways for efficient subsurface penetration. These insights provide a practical design rule: suppressing or minimizing exposure of such high-energy adsorption motifs - through appropriate surface texturing or orientation control - should make bcc-iron components less susceptible to hydrogen uptake and the associated embrittlement.