International Science Community Association Research Journal of Forensic Sciences 14 2 2026 07 29 Mechanical Explosion arising from in-situ Hydrogen generation in a fabricated cylinder: Fundamentals and Forensic awareness 27 33 EN Karthik G.I. Vaishnav 1 Department of Criminology & Forensic Science, Nehru Arts and Science College, Coimbatore, India K. Dinsha 2 Department of Forensic Science, M E S Kalladi College, Mannarkadu, Palakkad, Kerala, India R. Dhanya 3 Department of Criminology & Forensic Science, Nehru Arts and Science College, Coimbatore, India Kulkani Sudhanva G. 4 Department of Criminology & Forensic Science, Nehru Arts and Science College, Coimbatore, India S.S. Nidhin 5 Department of Criminology & Forensic Science, Nehru Arts and Science College, Coimbatore, India Bose Surajit 1 Department of Oral Maxillofacial Pathology Microbiology; Forensic Odontology, Kusum Devi Sunderlal Dugar Jain Dental College & Hospital, Ram Gopal Ghosh Road, Cossipore, Kolkata, West Bengal, India Shetty Rakshith 2 Department of Oral Maxillofacial Pathology Microbiology; Forensic Odontology, Kusum Devi Sunderlal Dugar Jain Dental College & Hospital, Ram Gopal Ghosh Road, Cossipore, Kolkata, West Bengal, India Bhattachrya Maumita 3 Department of Oral Maxillofacial Pathology Microbiology; Forensic Odontology, Kusum Devi Sunderlal Dugar Jain Dental College & Hospital, Ram Gopal Ghosh Road, Cossipore, Kolkata, West Bengal, India Sen Subhalakshmi 4 Department of Oral Maxillofacial Pathology Microbiology; Forensic Odontology, Kusum Devi Sunderlal Dugar Jain Dental College & Hospital, Ram Gopal Ghosh Road, Cossipore, Kolkata, West Bengal, India Chattopadhyay Jayanta 5 Department of Oral Maxillofacial Pathology Microbiology; Forensic Odontology, Kusum Devi Sunderlal Dugar Jain Dental College & Hospital, Ram Gopal Ghosh Road, Cossipore, Kolkata, West Bengal, India Ghosh Bitan 6 Department of Oral Maxillofacial Pathology Microbiology; Forensic Odontology, Kusum Devi Sunderlal Dugar Jain Dental College & Hospital, Ram Gopal Ghosh Road, Cossipore, Kolkata, West Bengal, India Rahangdale Labhini 1 Schiio of Biosciences and Bioengineering, Division of Forensic Science, DY Patil International University, Akurdi, Pune, Maharashtra-411044, India Dharmalingam Lokashree 2 Division of Forensic Science, Karunya Institute of Technology and Sciences, Coimbatore, Tamil Nadu-641114, India Mishra Manish Kumar 1 Department of Forensic Science, JAIN (deemed-to-be-University), Bengaluru, Karnataka, India Y. Kavya 2 Department of Forensic Science, JAIN (deemed-to-be-University), Bengaluru, Karnataka, India Lavanya T. 1 Department of Forensic Science, JAIN (Deemed-to-be University), Bengaluru, Karnataka, India M.K. Mishra 2 Department of Forensic Science, JAIN (Deemed-to-be University), Bengaluru, Karnataka, India . Chandrashekhara 1 Regional Forensic Science Laboratory, Govt. of Karnataka, Mysore, Karnataka, India H.S. Chandrashekhar 2 Regional Forensic Science Laboratory, Govt. of Karnataka, Mysore, Karnataka, India Limbitot Mahantappa 3 Regional Forensic Science Laboratory, Govt. of Karnataka, Hubballi, Karnataka, India B.S. Subhash 4 Regional Forensic Science Laboratory, Govt. of Karnataka, Mysore, Karnataka, India > Research Paper 2026 5 16 2026 07 29 Improvised metallic cylinders are gradually being misused for the generation of chemical gas without conformity to standard pressure-vessel design. The significant gas pressure and heat is generated by hydrogen formed from aluminium–alkali reactions, which creating conditions that may exceed the structural capacity of non-engineered vessel/containers. Present article describes the basic chemistry of generation of hydrogen using caustic soda and aluminium, the mechanism of pressure development along with the principles of engineering regulating safe pressure-vessel design. The practical and real life cylinder failure is presented as an anonymised case study. The detailed analysis reveals that the stress developed in present scenario that the fabricated aluminium vessel possessed insufficient wall thickness and weld reliability for the pressure potentially generated. The main aim of the present research article is to suggest the public and enforcement awareness concerning the dangers of using uncertified fabricated cylinders for the production of hydrogen for many purposes and highlights the requirement of the legal compliance and safety education. The present work inspected the structural integrity and failure potential of a fabricated aluminium cylinder repurposed for the hydrogen gas storage and generation. Copyright@ International Science Community Association