High cycle fatigue behaviors of API X65 pipeline steel welded joints in air and H2S solution environment

To investigate the mutual effect of hydrogen, microstructures and stress concentration on the fatigue failure, fatigue behaviors of X65 steel welded joints in both air and saturated H₂S solution were investigated at high cycle regime. The experimental result demonstrates that due to lower dislocation density observed by electron backscattered diffraction (EBSD), the fine grain heat affected zone (FGHAZ) is prone to induce cyclic strain localization and further lead to fatigue crack propagating along the FGHAZ in air. Furthermore, the quasi-cleavage with brittle-like fatigue striations and secondary crack on the fracture surface in saturated H₂S solution is attributed to hydrogen embrittlement. Moreover, compared with base metal (BM) and FGHAZ, the weld metal (WM) and coarse grain heat affected zone (CGHAZ) are composed of bainite and martensite/austenite (M/A) phase, and more sensitive to hydrogen. Therefore, the fatigue crack is prone to grow along the interface between WM and CGHAZ under the normal applied stress.     

Effects of internal hydrogen and surface-absorbed hydrogen on the hydrogen embrittlement of X80 pipeline steel

Effects of internal hydrogen and surface-absorbed hydrogen on hydrogen embrittlement (HE) of X80 pipeline steel were investigated by using different strain rate tensile test, annealing and hydrogen permeation tests. HE of X80 pipeline steel is affected by internal hydrogen and surface-absorbed hydrogen, and the latter plays a major role due to its higher effective hydrogen concentration. The HE susceptibility decreases with increasing the strain rate because it is more difficult for hydrogen to be captured by dislocations at the high strain rate. Annealing at 200 °C can weakened HE caused by internal hydrogen, while it has little effect on HE caused by surface-absorbed hydrogen. HE of X80 pipeline steel is mainly determined by the behavior of dislocation trapping hydrogen, which can be attributed to the interaction between hydrogen and dislocation.     

Hydrogen permeation and distribution at a high-strength X80 steel weld under stressing conditions and the implication on pipeline failure

Hydrogen permeation and distribution at pipeline welds is critical to integrity maintenance of the pipelines, especially for those made of high-strength steels. The situation becomes even more important under stressing conditions. In this work, metallographic characterization and micro-hardness measurements were conducted at an X80 steel weld. Potentiodynamic polarization and electrochemical hydrogen permeation testing were performance at various zones at the weld, along with numerical modeling of hydrogen distribution at the zones. The X80 steel contains a microstructure of bainite bundles and polygonal ferrite. There are more polygonal ferrite, fewer bainite and some segregated cementite at heat-affected zone (HAZ). The weld metal is featured with acicular ferrite and some grain boundary ferrite. HAZ softening occurs at the weld. The hardness of the weld metal, HAZ and base steel is about 290, 248 and 261 HV_0.2, respectively. There is the greatest corrosion current density, i.e., corrosion rate, at HAZ under both elastic and plastic stresses. An applied stress further increases the corrosion current density. Under the plastic stress of 1.1σ_ys (σ_ys is yield strength), the corrosion current densities of HAZ, base steel and weld metal are 41.04, 17.03 and 25.49 μA/cm², respectively. There are always the greatest hydrogen trapping density and the smallest hydrogen diffusivity at HAZ. Hydrogen, once penetrating the welded steel, tends to accumulate at the HAZ, compared with other two zones. When the welded steel is under stresses, especially a plastic stress (i.e., 1.1σ_ys), the hydrogen diffusivity and permeability decrease, while the subsurface hydrogen concentration and hydrogen trapping density increase remarkably. Plastic deformation favors the hydrogen permeation and trapping at weld, especially the HAZ, to elevate the susceptibility to hydrogen damage. The hydrogen distribution at different welding zones can be evaluated and determined by a developed modeling method.     

Effects of surface oxide films on hydrogen permeation and susceptibility to embrittlement of X80 steel under hydrogen atmosphere

Hydrogen embrittlement (HE) induced by hydrogen permeation is a serious threat to the hydrogen transmission pipeline. In this study, oxide films were prepared on X80 steel by applying high-temperature oxidation, blackening treatment and passivation in concentrated H₂SO₄, and their effects on hydrogen permeation and HE susceptibility of X80 substrate were studied by conducting hydrogen permeation tests and slow strain rate tension (SSRT) tests. A numerical diffusion model was established to quantitatively determine the resistance of these oxide films to hydrogen permeation. Results showed that the oxide film prepared by high-temperature oxidation presented the highest resistance to hydrogen permeation with the ?_m/?_f value of 3828, and the corresponding HE index decreased from 38.07% for bare X80 steel to only 4.00% for that covered with oxide film. The characteristic of the corresponding fracture surfaces changed from brittle features such as quasi cleavage facets and secondary cracks to typical ductile dimple feature.     

The dependence of hydrogen embrittlement on hydrogen transport in selective laser melted 304L stainless steel

The mechanical property and hydrogen transport characteristics of selective laser melting (SLM) 304L stainless steel were investigated by tensile tests and thermal desorption spectroscopy (TDS). The heat treatment affected the hydrogen embrittlement (HE) susceptibility and the treatment at 950 °C showed the larger HE effects. Cellular structures and melt-pool boundaries were dissolved at 850 and 950 °C, respectively. TDS results indicate that the hydrogen diffusivity of the as-received SLM 304L was lower than that of wrought 304L and the hydrogen diffusion activation energy increased with the recrystallisation degree, which was related to the dislocation density. Dislocations, rather than strain-induced martensite, were the main cause of HE owing to the high austenite stability of the samples. The pre-existing dislocations in the SLM 304L sample heat-treated at 950 °C for 4 h affected the hydrogen transport behaviour during sample stretching and led to severe HE.     

Combined effects of prior plastic deformation and sensitization on hydrogen embrittlement of 304 austenitic stainless steel

Austenite stainless steels (ASSs) may suffer from both cold deformation and sensitization prior to hydrogen exposure. There is scant data in literature on the combined effect of prior deformation and sensitization on the hydrogen embrittlement (HE) of ASSs. The present study investigated the combined effects of tensile plastic prestrain (PS) and 650 °C sensitization (ST) on the HE of 304 steel by hydrogen pre-charging and tensile testing. The results are explained by terms of pre-existing α′ martensite content. PS higher than 10% can enhance HE significantly by inducing severe α′ transformation prior to hydrogen exposure. Prior ST also enhances HE, but submitting the prestrained and α′-containing 304 steel to short-time ST can diminish the enhancement of HE by prestraining, as ST can cause the reversion of α′ to austenite, reducing pre-existing α′ content. It is inadvisable to make 304 steel be sensitized/welded firstly and deformed subsequently, even if the ST time is short such as what happens during welding, because this treating sequence can induce more α′ than prestraining alone, enhancing HE more significantly. Apparent hydrogen diffusivity can be related quantitatively to pre-existing α′ content, proving directly that α′ platelets can act as diffusion “highways” in ASSs. It is indicated that pre-existing α′ can enhance subsequently the HE of ASSs is because it can lead to a large amount of hydrogen entering the ASSs during hydrogen exposure by acting as diffusion “highways”. HE is enhanced by increasing hydrogen amount rather than by pre-existing α′ itself.     

Metallurgical and mechanical properties of hydrogen charged carbide-free bainitic weld metals

Hydrogen embrittlement is a major concern during the welding of high-strength steels. The susceptibility of the welds to hydrogen embrittlement increases with increase in weld strength. The ever-increasing demand to increase the strength of steels necessitates the development of novel welding procedures and fillers to produce welds of high strength and with resistance to hydrogen embrittlement. In this current work, the susceptibility of carbide-free bainitic weld metals to hydrogen embrittlement is studied with varying volume fractions of constituent phases. Using three different weld metal compositions, six different weld metal microstructures of carbide-free bainite were generated. The hydrogen saturation behaviour of the various weld metals was studied by cathodic electrolytic charging and subsequent diffusible hydrogen measurements by the hot extraction method. Tensile tests were conducted on various weld metals with and without hydrogen charging to evaluate their susceptibility to hydrogen embrittlement. The results show that the carbide-free bainite weld metals are highly resistant to hydrogen embrittlement despite their very high strength.     

Effect of microbial hydrogen consumption on the hydrogen permeation behaviour of AISI 4135 steel under cathodic protection

The feasibility of microbial hydrogen consumption to mitigate the hydrogen embrittlement (HE) under different cathodic potentials was evaluated using the Devanathan-Stachurski electrochemical test and the hydrogen permeation efficiency η. The hydrogen permeation efficiency η in the presence of strain GA-1 was lower than that in sterile medium. The cathodic potential inhibited the adherence of strain GA-1 to AISI 4135 steel surface, thereby reducing the hydrogen consumption of strain GA-1. The adherent GA-1 cells were capable of consuming ‘cathodic hydrogen’ and reducing the proportions of absorbed hydrogen, indicating that it is theoretically possible to control HE by hydrogen-consuming microbes.     

Suppression of hydrogen absorption into 304L austenitic stainless steel by surface low temperature gas carburizing treatment

Effect of low temperature gas carburizing (LTGC) on hydrogen absorption and hydrogen embrittlement (HE) susceptibility of 304L metastable austenitic stainless steel was investigated. The LTGC treatment imparted carburized layer on the steel surface with supersaturated solute carbon atoms (namely expanded austenite or S-phase) and more than 1 GPa surface compressive stress. Carburized layer thickness, carbon concentration level, residual compressive stress and hardness increased but hydrogen absorption decreased with increasing LTGC treatment time. Carburized surface layers had much higher austenite stability. The HE susceptibility of carburized steel was reduced due to the reduction of hydrogen absorption and the increment of austenite stability. The specimens whose residual compressive stresses were eliminated by tensile plastic straining also exhibited low hydrogen absorption during hydrogen charging, indicating that, besides the residual compressive stress, the supersaturated solute carbon atoms also have the ability to reduce hydrogen absorption. In addition, the results indicate that the supersaturated solute carbon atoms in the LTGC case can suppress hydrogen solubility without affecting diffusivity.     

Overview of hydrogen embrittlement in high-Mn steels

Hydrogen and fuels derived from it will serve as the energy carriers of the future. The associated rapidly growing demand for hydrogen energy-related infrastructure materials has stimulated multiple engineering and scientific studies on the hydrogen embrittlement resistance of various groups of high performance alloys. Among these, high-Mn steels have received special attention owing to their excellent strength – ductility – cost relationship. However, hydrogen-induced delayed fracture has been reported to occur in deep-drawn cup specimens of some of these alloys. Driven by this challenge we present here an overview of the hydrogen embrittlement research carried out on high-Mn steels. The hydrogen embrittlement susceptibility of high-Mn steels is particularly sensitive to their chemical composition since the various alloying elements simultaneously affect the material's stacking fault energy, phase stability, hydrogen uptake behavior, surface oxide scales and interstitial diffusivity, all of which affect the hydrogen embrittlement susceptibility. Here, we discuss the contribution of each of these factors to the hydrogen embrittlement susceptibility of these steels and discuss pathways how certain embrittlement mechanisms can be hampered or even inhibited. Examples of positive effects of hydrogen on the tensile ductility are also introduced.     

Effect of temperature on hydrogen embrittlement susceptibility of alloy 718 in Light Water Reactor environment

A 718 superalloy, presenting a standard microstructure, was mechanically tested under uniaxial tensile loading at 80 °C and 300 °C in Light Water Reactor environment after an exposure at 300 °C for 200 h. Hydrogen embrittlement mechanism was clearly observed. In order to identify the most influent metallurgical parameters on hydrogen embrittlement, three “model” microstructures were synthesized to test the efficiency of carbides, δ, γ′ and γ” precipitates to trap hydrogen at different temperatures. Results showed that γ′ and γ” played the major role on the hydrogen embrittlement susceptibility of the alloy even though carbides and δ precipitates could also act as hydrogen traps and influence the final rupture mechanism. Results also characterized the influence of temperature on the fracture modes.     

Investigation for enhancing the resistance of H-induced delayed cracking for martensitic steel by quenching tempering and quenching partitioning: Influence of microstructure on hydrogen embrittlement and cracking behavior

The objective of the present study is to enhance the hydrogen embrittlement (HE) of the commercial martensitic steel (QT220). For this purpose, the heat treatments of quenching tempering and quenching partitioning are conducted, labeled as QT400 and Q&QP400, respectively. Compared to QT220, the mechanical properties of the both heat-treated specimens are reduced, nevertheless, the HE resistance is extremely promoted, resulting from the lesser dislocations, the more Mo_yC_x, and the existence of the strained interface of cementite. Besides the above favorable factors, the presence of the ferrite is another important factor which contributes to the lowest HE susceptibility in Q&QP400, resulting from the propagation's inhibition of hydrogen induced cracks (HICs) by ferrite. The HICs behavior of QT220, QT400 and Q&QP400 are mainly influenced by the dislocation glide, the cementite at the high angle boundaries and ferrite, respectively, mainly resulting in the fractographs of quasi-cleavage, intergranular and finely fragmented quasi-cleavage, respectively. In addition, HICs always deflect when propagating to the RD//<112～114> orientations, providing a valuable direction for research to enhance the HE resistance in the future.     

Improvement of hydrogen embrittlement resistance of 2205 duplex stainless steel by laser peening

The hydrogen embrittlement (HE) resistance of 2205 duplex stainless steel (DSS) treated with laser peening (LP) with different laser power densities was studied. The results show that LP changes the morphologies and distribution of ferrite phase and austenitic phase, thus changes the path of hydrogen transportation and diffusing. LP-induced grain refinement provides more tortuous grain boundaries that increases the difficulty of hydrogen atoms to penetrate them. The beneficial LP-induced microstructures interacts (e.g. dislocation entanglements, dislocation walls, mechanical twins) and helps to trap the hydrogen atoms, reducing their mobility ability. The hydrogen determination test provides direct evidence that LP reduced the amount of hydrogen penetration into the material. In addition, the tensile fracture exhibits that the average depth of the brittle region was inversely proportional to the laser power density, suggesting that an increase in laser power density can reduce the HE sensitivity of 2205 DSS.     

Effect of specific microstructures on hydrogen embrittlement susceptibility of a modified AISI 4130 steel

The focus of this study is to analyze hydrogen embrittlement susceptibility of a modified AISI 4130 steel by means of incremental step loading tests. Three different microstructures with a hardness of 40 HRC were analyzed: martensite with large and small prior austenite grains and dual-phase (martensite/ferrite). According to the results, the dual-phase microstructure presented the lowest hydrogen embrittlement susceptibility and martensite with large prior austenite grains, the highest. This behavior was attributed to the lower fraction of high-angle boundaries presented by the martensite with large prior austenite grains, which led to a higher diffusible hydrogen content. Moreover, the ferrite local deformation in the dual-phase microstructure enhanced its hydrogen embrittlement resistance by lowering the stress concentration. A synergic effect of decohesion and localized plasticity was identified on the hydrogen induced fracture of the tested microstructures leading to an intergranular + quasi-cleavage fracture in the martensite and quasi-cleavage in the dual-phase microstructure.     

Effect of cyclic plastic deformation on hydrogen diffusion behavior and embrittlement susceptibility of reeling-pipeline steel weldments

The hydrogen embrittlement (HE) susceptibility and hydrogen permeation behavior of reeling-pipeline welded joint with/without cyclic plastic deformation (CPD) were studied using the electrochemical hydrogen charging technique. Results indicated that the surface of welded joint emerged hydrogen-induced damage containing cracks and blisters. The degree of hydrogen-induced damage increased with the increase of hydrogen charging time and current density. When the hydrogen charging current density and time was 50 mA/cm² and 4 h, respectively, the area ratio of hydrogen-induced damage of overall welded joint with CPD process was reduced from 6.61% to 2.28%, and the damage ratio of different sub-zones in welded joint was also decreased. The oxidized inclusions enriching Al–Mg–Ca elements acted as the initiation sites for hydrogen-induced damages. The effective diffusion coefficient of as-welded joint was 2.63 × 10⁻⁶ cm²/s, while that of welded joint with CPD showed a smaller value of 1.36 × 10⁻⁶ cm²/s. The welded joint with CPD process presented better resistance to HE, which was attributed to the increased density of hydrogen traps and the formation of dislocation cells to disperse hydrogen uniformly and reduce the possibility of local accumulation and recombination of diffusible hydrogen. Sub-zones in welded joint without CPD process were considerably more sensitive to hydrogen-induced damage, which indicated the important role of microstructure and dislocation density in HE mechanisms. The order of HE susceptibility from low to high was weld metal, base metal and heat affected zone.     

Hydrogen gaseous embrittlement effect over mechanical properties of an experimental X-120 microalloyed steel subjected to heat treatments and different cooling rates

This research work aimed to determine the hydrogen gas pressure effect on the mechanical properties of an experimental X-120 microalloyed steel, subjected to heat treatments and quenched in different mediums. The steel in its as-received condition was reheated at 900 °C and quenched in spray water (900QSW), pressurized air (900QPA), and emulsion of water-oil medium (900QWO) which produces complex microstructures formed by martensite–bainite–acicular ferrite; otherwise, reheated at 820 °C and quenched in oil media (820QO) which produces a banded martensite-polygonal ferrite microstructure. To determine the hydrogen embrittlement susceptibility, in-situ tension tests were developed at 1, 4, and 7 MPa of hydrogen gas pressure. The results showed that as hydrogen gas pressure increases, the mechanical properties reduce in all quenched conditions, being the most susceptible condition the 820QO sample which presented the higher embrittlement index; on the contrary, the less susceptible condition was the 900QPA sample.     

The influence of intergranular and interphase boundaries and δ-ferrite volume fraction on hydrogen embrittlement of high-nitrogen steel

We study the effect of grain size of austenitic and ferritic phases and volume fraction of δ-ferrite, which were obtained in different solution-treatment regimes (at 1050, 1100, 1150 and 1200 °C), on hydrogen embrittlement of high-nitrogen steel (HNS). The amount of dissolved hydrogen is similar for the specimens with different densities of interphase (γ-austenite/δ-ferrite) and intergranular (γ-austenite/γ-austenite, δ-ferrite/δ-ferrite) boundaries. Despite, the susceptibility of the specimens to hydrogen embrittlement, depth of the hydrogen-assisted surface layers, hydrogen transport during tensile tests and mechanisms of the hydrogen-induced brittle fracture all depend on grain size and ferrite content. The highest hydrogen embrittlement index I_H = 32%, the widest hydrogen-affected layer and a pronounced solid-solution hardening by hydrogen atoms is typical of the specimens with the lowest fraction of the boundaries. Even though fast hydrogen transport via coarse ferritic grains provides longer diffusion paths during H-changing, the width of the H-affected surface layer in the dual-phase structure of the HNS specimens is mainly determined by the hydrogen diffusivity in austenite. In tension, hydrogen transport with dislocations increases with the decrease in density of boundaries due to the longer dislocation free path, but stress-assisted diffusion transport does not depend on grain size and ferrite fraction. The contribution from intergranular fracture increases with an increase in the density of intergranular and interphase boundaries.     

Hydrogen embrittlement of the coarse grain heat affected zone of a quenched and tempered 42CrMo4 steel

The coarse grain heat affected zone (CG-HAZ) of welds produced in a quenched and tempered 42CrMo4 steel was simulated by means of a laboratory heat treatment consisting in austenitizing at 1200 °C for 20 min, oil quenching and finally applying a post weld heat treatment at 700 °C for 2 h (similar to the tempering treatment previously applied to the base steel). A tempered martensite microstructure with a prior austenite grain size of 150 μm and a hardness of 230 HV, similar to the aforementioned CG-HAZ weld region, was produced. The effect of the prior austenite grain size on the hydrogen embrittlement (HE) behaviour of the steel was studied comparing this coarse-grained microstructure with that of the fine-grained base steel, with a prior austenite grain size of 20 μm.The specimens used in this study were charged with hydrogen gas in a reactor at 19.5 MPa and 450 °C for 21 h. Cylindrical specimens were used to determine hydrogen uptake and hydrogen desorption behaviour. Smooth and notched tensile specimens tested under different displacement rates were also used to evaluate HE.Embrittlement indexes, EI, were generally quite low in the case of hydrogen pre-charged tensile tests performed on smooth tensile specimens. However, very significant embrittlement indexes were obtained with notched tensile specimens. It was observed that these indexes always increase as the applied displacement rate decreases. Moreover, hydrogen embrittlement indexes also increase with increasing prior austenite grain size. In fact, the embrittlement index related to the reduction in area, EI_(RA), reached values of over 20% and 50% for the fine and coarse grain size steels, respectively, when tested under the lowest displacement rates (0.002 mm/min).A comprehensive fractographic analysis was performed and the main operative failure micromechanisms due to the presence of internal hydrogen were determined at different test displacement rates. While microvoids coalescence (MVC) was found to be the typical ductile failure micromechanism in the absence of hydrogen in the two steels, brittle decohesion mechanisms (carbide-matrix interface decohesion, CMD, and martensitic lath interface decohesion, MLD) were observed under internal hydrogen. Intergranular fracture (IG) was also found to be operative in the case of the coarse-grained steel tested under the lowest displacement rate, in which hydrogen accumulation in the process zone ahead of the notch tip is maximal.     

Hydrogen effects on X80 pipeline steel in high-pressure natural gas/hydrogen mixtures

Blending hydrogen into existing natural gas pipelines has been proposed as a means of increasing the output of renewable energy systems such as large wind farms. X80 pipeline steel is commonly used for transporting natural gas and such steel is subjected to concurrent hydrogen invasion with mechanical loading while being exposed to hydrogen containing environments directly, resulting in hydrogen embrittlement (HE). In accordance with American Society for Testing and Materials (ASTM) standards, the mechanical properties of X80 pipeline steel have been tested in natural gas/hydrogen mixtures with 0, 5.0, 10.0, 20.0 and 50.0vol% hydrogen at the pressure of 12 MPa. Results indicate that X80 pipeline steel is susceptible to hydrogen-induced embrittlement in natural gas/hydrogen mixtures and the HE susceptibility increases with the hydrogen partial pressure. Additionally, the HE susceptibility depends on the textured microstructure caused by hot rolling, especially for the notch specimen. The design calculation by the measured fatigue data reveals that the fatigue life of the X80 steel pipeline is dramatically degraded by the added hydrogen.     

Unveiling the role of hydrogen on the creep behaviors of nanograined α-Fe via molecular dynamics simulations

Hydrogen embrittlement (HE) substantially deteriorates the mechanical properties of metals. The HE behavior of nanograined (NG) materials with a high fraction of grain boundaries (GBs) may significantly differ from those of their coarse-grained counterparts. Herein, molecular dynamics (MD) simulations were performed to investigate the HE behavior and mechanism of NG α-Fe under creep loading. The effects of temperature, sustained stress, and grain size on the creep mechanism was examined based on the Mukherjee-Bird-Dorn (MBD) equation. The deformation mechanisms were found to be highly dependent on temperature, applied stress, and grain size. Hydrogen charging was found to have an inhibitory effect on the GB-related deformation mechanism. As the grain size increased, the HE mechanism transitioned from H-induced inhibition of GB-related deformation to H-enhanced GB decohesion. The current results might provide theoretical guidance for designing NG structural materials with low HE sensitivity and better mechanical performance.