Evaluation of hydrogen induced cracking behavior of API X70 pipeline steel at different heat treatments

The microstructure of API X70 pipeline steel was modified by applying different heat treatments including water-quenched, water-sprayed, and water-quenched and tempered. Hydrogen induced cracking behavior was investigated on the X70 steel at these heat treatments. Two test methods, Japanese Industrial Standard (JIS) and vacuum thermal desorption, were used to release hydrogen from reversible and irreversible traps. The experimental results showed that the highest amount of discharged hydrogen in reversible and irreversible traps was related to the water-sprayed and as-received steels. The hydrogen discharged content from reversible traps reached to a saturation level after 8 h of charging, and it decreased considerably when the steels were charged for 15 h and 24 h. Hydrogen discharge tests proved that a higher amount of hydrogen inside steel is not a reliable measure for HIC evaluation. HIC test results also document that the water-quenched steel with agglomerated martensite particles had the highest susceptibility to HIC. Texture study results show that a low fraction of important texture components, such as {023}, {321} and {332}, cannot be reliably used to evaluate HIC. As a result, a novel method of manufacturing of pipeline steels with an optimized texture is required to increase safety and reliability of transportation of sour gas and oil.     

Evaluation of the cementite morphology influence on the hydrogen induced crack nucleation and propagation path in carbon steels

The effect of cementite morphology on the crack initiation and growth path was studied using in situ electrochem-ical micro-cantilever bending (ECCB) technique under hydrogen (H) charging. Two carbon steels with lamellar cementite morphology (pearlitic microstructure) and spherical or broken lamellas cementite morphology (spheroidite microstructure), both with approximately the same carbon equivalent, were used in this study. The ECCB tests were performed in H-free and two H charging steps with ?1050 mV and ?1550 mV charging potential versus Ag/AgCl reference electrode. The results show that both materials are resistant to crack initiation in the H-free condition while under ?1050 mV charging, crack propagates through the grain boundaries in a tortuous path in spheroidite mi-crostructure and the lamellar microstructure displayed a higher strength with small cracks propagating through both the grain boundaries and the lamellas. A drastic load decrease in the load-displacement (L-D) curve happened under ?1550 mV charging for both microstructures accompanied by a straight crack growth path in spheroidite microstruc-ture, independent of grain boundaries or ferrite-cementite interfaces while a competition between the shear crack growth mechanism and the interfacial cracking determines the crack growth path in the lamellar microstructure.     

Effects of cryogenic and tempered treatment on the hydrogen embrittlement susceptibility of TRIP-780 steels

Cryogenic and Tempered (CT) treatments were performed on commercial TRIP 780 steels in order to reduce the hydrogen embrittlement (HE) susceptibility. The HE behavior was assessed immediately after cathodically hydrogen charging on both CT treated and untreated samples. Slow strain-rate tensile (SSRT) tests were conducted to evaluate their HE performance. It is shown that samples with CT treatments behave higher resistance to HE comparing with their untreated counterparts. Meanwhile, microstructure characterization and magnetization measurements were adopted to reveal the evolution of retained austenite (A_r) and its stabilization due to CT treatment. Moreover, hydrogen-induced cracking (HIC) accompanied with martensite phase transformation in TRIP steel was studied by electron backscattering diffraction (EBSD) technique and it was proved that cracks initiated from the fresh untempered martensite inherited from phase transformation of unstable A_r upon straining. Finally, results in this study demonstrate the relationship between A_r stability and HE susceptibility, and provide a possible solution to reduce HE susceptibility in TRIP steels.     

Fracture toughness properties of HIC susceptible carbon steels in sour service conditions

Hydrogen Induced Cracking (HIC) in carbon steels is a well-studied mechanism, where diffusing hydrogen atoms accumulates at the steel imperfections/laminations to create gaseous hydrogen with very high pressure, leading to initiation and growth of internal cavities, so-called HIC. Measurements of relevant fracture toughness properties of non-HIC resistant steels in hydrogen environment is critical to predict and assess the initiation and growth of HIC. The present work attempts to quantify the effect of hydrogen on the fracture toughness properties (K_Q and CTOD) of an API X42 pipeline steel under simulated H₂S in-service conditions. The fracture toughness properties are measured in TL and SL directions: perpendicular and parallel to the pipeline wall thickness, respectively, following ASTM E1820, standard. Since the X42 is a non-HIC resistant steel, the measurement of the fracture toughness properties in the SL direction is more relevant in terms of HIC initiation and growth than fracture toughness properties in the TL direction. Indeed, parallel to the thickness of the pipeline wall, X42 steel shows microstructural features prone to HIC formation and growth. Steady state H₂S in-service conditions were simulated by charging the specimen for 48 h using a special electrolytic solution and then tested (ex-situ) to evaluate the fracture toughness properties. The steady state H₂S environment was obtained by measuring the Hydrogen Concentration (CH) in the bulk of the specimen, using Thermal desorption Spectroscopy at three levels of CH. It was observed that the K_Q was not affected in the SL direction, while it was reduced in the TL direction for 1.5 ppmw of CH. The CTOD showed mixed results in the TL direction while it was significantly reduced in the SL direction reaching a saturation at 1 ppmw of CH. Besides, microstructural analyses showed that the presence of inclusions coalescence in form of dimples promote the early failure, which is more pronounced in the hydrogen environment especially at higher levels of CH.     

Improving hydrogen induced cracking resistance of high strength acid-resistant submarine pipeline steels via trace-Mg treatment

Hydrogen induced cracking (HIC) is one of the biggest service risks faced by high-strength acid-resistant submarine pipeline steel. In this work, we reported a low-carbon, low-cost and high-efficient method for remarkably improving HIC resistance of the high-strength acid-resistant submarine pipeline steels by trace-Mg treatment. The results showed that the non-metallic inclusions steels were obviously refined, softened, spheroidized and dispersed by trace-Mg treatment, the modified “core-shell” or like “core-shell” structure inclusions had a larger critical size for HIC initiation and a higher saturated hydrogen concentration, and then effectively trapping more hydrogen, dispersing hydrogen pressure and reducing the diffused hydrogen content, thus effectively improving the HIC resistance. With the further increasing of Mg contents, the inclusion modification would be weakened, the hydrogen trapping efficiency decreased, and the HIC susceptibility of the tested steel increased again. In the research range, the tested steels treated with 4  ppm Mg present the lowest HIC susceptibility.     

Hydrogen induced cracking susceptibility in different layers of a hot rolled X70 pipeline steel

Hydrogen induced cracking (HIC) behaviour was investigated in three layers of RD–ND plane. HIC test showed that all cracks initiated from the mid-thickness of the RD–ND plane and propagated in the rolling direction of the steel plate. Hydrogen permeation test results showed a lower permeability and diffusivity coefficient for the third layer resulting in the highest density of traps and consequently HIC susceptibility. Considering the HIC test and crystallographic texture measurements, cracks initiated from the grain boundaries associated with {100} grain orientation and arrested in regions with some strong texture components, such as {110}//ND, {112}//ND, and possibly {332}//ND. The role of HABs and CSLs boundaries was important in crack propagation.     

Origin of deformation twins and their influence on hydrogen embrittlement in cold-rolled austenitic stainless steel

The effect of cold rolling on hydrogen embrittlement in stable 18Cr–1Mn–11Ni-0.15 N austenitic stainless steels was investigated. Alloy plates were cold-rolled to 15% or 30% reduction, then pre-charged with hydrogen and subjected to tensile testing with slow strain rate. Hydrogen-induced degradation of tensile elongation became increasingly severe with the increase in the degree of cold rolling. During cold rolling, deformation twins with various orientations were actively generated, and twins with specific orientations were vulnerable to hydrogen-induced cracking. Cold rolling also increased the density of defects, and thereby facilitated penetration of hydrogen into the steels. The combination of cracks generated at the twin boundaries, and the promoted hydrogen diffusion caused severe hydrogen embrittlement in the cold-rolled steels.     

Effect of Ce content on the hydrogen induced cracking of X80 pipeline steel

In this study, the effect of Ce content on hydrogen induced cracking (HIC) of X80 pipeline steel has been investigated. The results show that as the Ce content increased from 0 wt% to 0.0042 wt%, 0.016 wt% and 0.024 wt%, the HIC susceptibility of tested steels decreased first and then increased. The steel containing 0.016 wt% Ce possessed the lowest HIC susceptibility because Ce modified inclusions, promoted the formation of acicular ferrite, and decreased the number of hydrogen traps and intergranular cracks.     

Correlation between grain size variation and hydrogen embrittlement in a cost-effective Fe40Mn40Ni10Cr10 austenitic medium entropy alloy

The effect of grain size variation (11 μm, 34 μm) on the hydrogen-induced tensile properties degradation of a Co-free cost-effective Fe₄₀Mn₄₀Ni₁₀Cr₁₀ austenitic medium entropy alloy was investigated using a slow strain rate test. Despite improving both strength and ductility with decreasing the grain size in non-charged conditions, the fine-grain alloy showed a higher relative elongation loss after electro-chemical hydrogen charging. The larger ductility loss in the fine-grain alloy was ascribed to the fast propagation rate of major intergranular cracks and the drastic strain hardening rate drop of the alloy under hydrogen charging. The Schmid factor analysis showed that the enhanced dislocation activity in the fine-grain alloy compared with coarse-grain one was responsible for rapid hydrogen transfer to the grain boundaries, fast dislocation pile-up behind the grain boundaries, and, consequently, more severe hydrogen embrittlement. The significant stress concentration near the grain boundaries and fast intergranular crack propagation were recognized to be the main reason for premature fracture in fine-grain alloy.     

Hydrogen embrittlement and hydrogen diffusion behavior in interstitial nitrogen-alloyed austenitic steel

The susceptibility to hydrogen embrittlement and diffusion behavior of hydrogen were evaluated in interstitial nitrogen-alloyed austenitic steel QN1803 and 304 and 316 L stainless steels. The amount of transformed martensite and the activation energy of hydrogen diffusion were revealed via electron backscattering diffraction and thermal desorption spectroscopy. The austenite stability of QN1803 during the deformation process was higher than that of 304 and 316 L. However, the hydrogen content of QN1803 was high because of the small grain size and low activation energy of hydrogen diffusion. For the stable QN1803 and 316 L austenitic steels, martensite had no evident harmful effect because of its discrete distribution. A planar dislocation slip was observed in QN1803 during deformation. Hydrogen charging enhanced dislocation mobility, leading to severe strain localization. Thus, the severe strain in QN1803 promoted microcracking.     

Evolution of microstructure and texture in pipeline steels at different TMCP procedures with regard to hydrogen induced cracking

SEM and EBSD techniques are used to evaluate hydrogen induced cracking susceptibility in API X70 pipeline steels produced by thermo-mechanical controlled process (TMCP) in laboratory scale. Based on the observations, there is no dominant texture in the specimens and the grains are randomly distributed. Different TMCP parameters and rolling processes generates different grain size, and grains are often elongated along the rolling direction. The results also show that cooling rate is another factor affecting the grain size. A high cooling rate does not allow the grains to grow. The reason for the transgranular type of cracking might be the strong grain boundaries in ambient temperatures which prevents the intergranular cracking. Based on experiments, the hydrogen environment does not have permanent effects on the mechanical properties of the investigated specimens. The electrochemical hydrogen charging experiment shows that the grain refinement improves the resistance to hydrogen embrittlement.     

Finite element modeling of HIC propagation in pipeline steel with regard to experimental observations

In this research, hydrogen induced cracking (HIC) phenomenon in pipeline steel has been investigated by finite element modeling (FEM) with the help of experimental observations. Abaqus software has been utilized to model the crack. To this, first an API 5L X70 pipeline steel was electrochemically charged by hydrogen for 8 h to create different types of HIC cracks. Then, SEM was used to observe different types of hydrogen cracks. Based on the observations, most of HIC cracks were observed at the center of cross section where center segregation of some elements occurred. The results showed that HIC cracks propagated in stepwise, sinusoidal, straight and disordered manner. Moreover, HIC crack nucleated from a point with high stress concentration factor which was between non-metallic inclusion or void and metal matrix. The initiated micro-cracks from two neighbor inclusions link together to form a long HIC crack. Based on the experimental observations and FEM modeling, it was concluded that the driving force for the HIC crack propagation is the presence of hydrogen at the crack tip after it is initiated. Crack tip usually acts as a very small void and the combination of hydrogen atoms makes a high pressure which propel the crack forward. Moreover, the HIC crack propagation path was predicted by fracture mechanics approach showing that the J-integral had its maximum amount when the HIC crack tended to propagate horizontally.     

Hydrogen trapping and hydrogen induced cracking of welded X100 pipeline steel in H2S environments

Hydrogen induced cracking (HIC) susceptibility of the welded X100 pipeline steel was evaluated in NACE “A” solution at room temperature according to the NACE TM0284-2011 standard. Both the kinetic parameters of the permeability $\left(J_{\infty }L\right)$, the apparent diffusivity (D_app) and the concentration of reversible and irreversible hydrogen in the base metal and welded joint of X100 pipeline steel were quantitatively investigated by hydrogen permeation test. The results showed that the welded joint with an inhomogeneous microstructure had a higher trap density and more susceptible to HIC due to two orders of magnitude larger in the concentration of irreversible hydrogen than that of base metal, though all presenting poor HIC resistance for both base metal and the welded joint. The HIC cracks initiated from the inclusions enriching in Al, Ca, Si, Mn. The cracks are primarily transgranular, accompanying with limited intergranular ones.     

Hydrogen induced cold cracking studies on armour grade high strength,quenched and tempered steel weldments

Quenched and tempered (Q&T) steels are prone to hydrogen induced cracking (HIC) in the heat affected zone after welding. The use of austenitic stainless steel (ASS) consumables to weld the above steel was the only available remedy because of higher solubility for hydrogen in austenitic phase. The use of stainless steel consumables for a non-stainless steel base metal is not economical. Hence, alternate consumables for welding Q&T steels and their vulnerability to HIC need to be explored. Recent studies proved that low hydrogen ferritic (LHF) steel consumables can be used to weld Q&T steels, which can give very low hydrogen levels in the weld deposits. In this investigation an attempt has been made to study the influence of welding consumables and welding processes on hydrogen induced cold cracking of armour grade Q&T steel welds by implant testing. Shielded metal arc welding (SMAW) and flux cored arc welding (FCAW) processes were used for making welds using ASS and LHF welding consumables. ASS welds made using FCAW process offered a higher resistance to HIC than all other welds considered in this investigation.     

Combined impact of elastic stress,prestrain and electrochemical charging on the hydrogen-induced cracking of high-strength steel

The elastic stress, prestrain and electrochemical hydrogen charging were controlled separately using a stress ring to investigate their roles in the initiation of hydrogen-induced cracks. The brittle features of hydrogen charging-induced damages, i.e., a mixture of quasi-cleavage and intergranular cracks, on the fracture surface were confirmed for a high-strength steel, made possible by applying degassing and tension-to-fracture to the hydrogen-charged specimens. The hydrogen charging-induced cracks eliminated the ductility of material, leading to premature fracture before the yield point in subsequent tensile tests. The strong dependence of hydrogen-induced cracking sensitivity on hydrogen concentration and hydrogen charging time was observed. X-ray microtomography and tensile tests were also utilized to investigate the effect of inclusions on crack formation. This study contributes to the understanding of the combined effects of residual stress and hydrogen on the cracking of deformed steel plates.     

Effect of vanadium content on hydrogen embrittlement of 1400 MPa grade high strength bolt steels

In this work, the hydrogen embrittlement (HE) characteristics of 1400 MPa bolt steels with three different vanadium contents of 0, 0.17 wt% and 0.34 wt% were evaluated. The characteristics of the microstructure and dislocation density of the experimental steels were analyzed, and their effects on HE were also discussed. The results showed that with increasing V content, the HE resistance of the experimental steels was improved, and the experimental steel with the highest V content possessed the best HE resistance. The V-precipitates of steels with V contents of 0.17 wt% and 0.34 wt% were reversible hydrogen traps, and the inhibitory effect of V-precipitates on hydrogen-dislocation interactions improved HE resistance. In addition, a lower dislocation density and finer martensitic structure were also beneficial for hindering hydrogen-induced cracking (HIC).     

Hydrogen induced blister cracking and mechanical failure in X65 pipeline steels

The present work aims to investigate the role of hydrogen induced blisters cracking on degradation of tensile and fatigue properties of X65 pipeline steel. Both tensile and fatigue specimens were electrochemically charged with hydrogen at 20 mA/cm² for a period of 4 h. Hydrogen charging resulted in hydrogen induced cracking (HIC) and blister formation throughout the specimen surface. Nearly all the blisters formed during hydrogen charging showed blister wall cracking (BWC). Inclusions mixed in Al-Si-O were found to be the potential sites for HIC and BWC. Slow strain rate tensile (SSRT) test followed by fractographic analysis confirmed significant hydrogen embrittlement (HE) susceptibility of X65 steel. Short fatigue crack growth framework, on the other hand, specifically highlighted the role of BWC on accelerated crack growth in the investigated material. Coalescence of propagating short fatigue crack with BWC resulted in rapid increase in the crack length and reduced the number of cycles for crack propagation to the equivalent crack length.     

Hydrogen related degradation in pipeline steel: A review

To support our increasing energy demand, steel pipelines are deployed in transporting oil and natural gas resources for long distances. However, numerous steel structures experience catastrophic failures due to the evolution of hydrogen from their service environments initiated by corrosion reactions and/or cathodic protection. This process results in deleterious effect on the mechanical strength of these ferrous steel structures and their principal components. The major sources of hydrogen in offshore/subsea pipeline installations are moisture as well as molecular water reduction resulting from cathodic protection. Hydrogen induced cracking comes into effect as a synergy of hydrogen concentration and stress level on susceptible steel materials, leading to severe hydrogen embrittlement (HE) scenarios. This usually manifests in the form of induced-crack episodes, e.g., hydrogen induced cracking (HIC), stress-oriented hydrogen induced cracking (SOHIC) and sulfide stress corrosion cracking (SSCC). In this work, we have outlined sources of hydrogen attack as well as their induced failure mechanisms. Several past and recent studies supporting them have also been highlighted in line with understanding of the effect of hydrogen on pipeline steel failure. Different experimental techniques such as Devanathan–Stachurski method, thermal desorption spectrometry, hydrogen microprint technique, electrochemical impedance spectroscopy and electrochemical noise have proven to be useful in investigating hydrogen damage in pipeline steels. This has also necessitated our coverage of relatively comprehensive assessments of the effect of hydrogen on contemporary high-strength pipeline steel processed by thermomechanical controlled rolling. The effect of HE on cleavage planes and/or grain boundaries has prompted in depth crystallographic texture analysis within this work as a very important parameter influencing the corrosion behavior of pipeline steels. More information regarding microstructure and grain boundary interaction effects have been presented as well as the mechanisms of crack interaction with microstructure. Since hydrogen degradation is accompanied by other corrosion-related causes, this review also addresses key corrosion causes affecting offshore pipeline structures fabricated from steel. We have enlisted and extensively discussed several recent corrosion mitigation trials and performance tests in various media at different thermal and pressure conditions.     

On the role of hydrogen in the stress corrosion cracking behavior of Q345R steel in HF vapor environment

The stress corrosion cracking (SCC) behavior of Q345R steel in hydrofluoric acid (HF) vapor environment was investigated. It is shown that Q345R has a high susceptibility to SCC in HF vapor environment, which is negatively correlated with the strain rate. Several different crack morphologies and cracking factors are verified: flat cracks in ferrite are associated with anodic dissolution triggered by micro-galvanic corrosion, and porous cracks at the pearlite and pearlite-ferrite interfaces are mainly influenced by hydrogen. The results of hydrogen charging tests show that pre-charging has little effect on the hydrogen embrittlement of Q345R steel, while in-situ charging leads to severe brittle fracture of the material, because hydrogen interacts with large number of moving dislocations generated by in-situ stretching process and penetrates more readily into the material. The synergistic relationship between hydrogen and dislocation motion is found to be the main mechanism for the transition from ductile to brittle fracture.     

Hydrogen and radiation embrittlement of CrMoV and CrNiMoV ferritic RPV steels

Hydrogen embrittlement of low-alloy steels has been investigated in relation to its dependence on hydrogen trapping and release, on the electrolytic hydrogen charging parameters, and on irradiation. The interaction of hydrogen with the structure of irradiated and unirradiated steels at higher charging current densities causes structural defects which can lead to a loss of ductility of the steel even after hydrogen release. The presence and the character of grain boundaries, secondary phases and other defects in the steel structure are of great importance from the viewpoint of the hydrogen embrittlement effect.