SAE J3121_202202

The scope of this document is to provide an overview of the risks and protective precautions to ensure safe and effective testing procedures for the test personnel and the vehicle during the testing of a hydrogen fuel cell vehicle. The main risks associated with a hydrogen fuel cell vehicle are the fuel cell stack, hydrogen storage vessel, fuel cell system components and the high voltage battery. Risks could be summarized from the battery into thermal runaway possibly leading to fire or explosion, electrolyte spillage and electrical shock or electrocution. The hydrogen fuel cell system risks include electrical shock or electrocution and possible release of hydrogen gas (if tested with). Vehicle crash testing protection should be coordinated with the system or component manufacturer(s) suggestions. Precautions should be taken with the handling, transportation, and storage of the vehicle pre-crash and post-crash. This document was written to provide and an understanding of the risks and precautions and should be reviewed periodically to ensure conformance to new technological developments. There are special risks associated with the destructive testing of hydrogen fuel cell vehicles (FCVs), fuel cell hybrid vehicles (FCHVs), and fuel cell electric vehicles (FCEVs). This information report is intended to inform crash test personnel and facility managers of the risks, and some countermeasures to help mitigate the risks to lab personnel safety, the facility, and the equipment used in the testing. This report is not intended as a stand-alone procedure for FCV crash test safety, as the technology is still evolving and cannot be represented fully in this context.