Hydrogen environment embrittlement of orbital welded austenitic stainless steels at −50 °C

Different stainless steels were TIG orbital welded resulting in δ-ferrite contents up to 5% in the weld seam. Tensile specimens tested in He atmosphere did fracture at the fusion line/heat affected zone (FL/HAZ), which is the typical failure mode for welded structures. In contrast, all specimens (except the one made of 1.4301) tested in H₂ did not fracture in the FL/HAZ but in the base material. These results clearly show that for the tests performed here δ-ferrite contents up to 5% did not enhance susceptibility to HEE compared to the base material.     

Hydrogen embrittlement of super duplex stainless steel in acid solution

Super duplex stainless steel (SDSS) is a good choice of material when resistance to harsh environments is needed. Despite the material’s excellent corrosion resistance and high strength, a number of in-service failures have been recorded. The root cause of these failures was environmentally induced cracking initiated at manufacturing and in-service metallurgical defects. In this study the hydrogen embrittlement of pre-strained super duplex stainless steel specimens was investigated after 48 h cathodic charging in 0.1 M H₂SO₄. The metallurgical changes that resulted from four levels of cold work (4, 8, 12, and 16% plastic strain) were considered and their effect on the embrittlement of the SDSS alloy was investigated. After hydrogen charging, the specimens were pulled immediately to failure and the mechanical properties evaluated. The obtaining fracture morphology was investigated using low and high magnification microscopy. Experimental results indicated that charging the super duplex stainless steel alloy with hydrogen caused varying degrees of embrittlement depending on cold work level. Increasing cold work resulted in a reduction of the elongation to failure. Microscopic investigation confirmed the significant effect of cold work on the hydrogen embrittlement susceptibility of the super duplex stainless steel alloy investigated.     

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.     

Nanomechanical characterization of the hydrogen effect on pulsed plasma nitrided super duplex stainless steel

Pulsed plasma nitriding (PPN) is used to nitride super duplex stainless steel (SDSS). Different analytical techniques are used to characterize the nitride layer on both ferrite and austenite phases existing in the SDSS. In-situ electrochemical nanoindentation is used to examine the effect of electrochemically charged hydrogen on the mechanical properties of both the SDSS substrate metal and the nitride layer. By applying this method, we were able to trace the changes in the mechanical properties due to the absorption of atomic hydrogen. The results clearly show that the hydrogen charging of the nitriding layer can soften the layer and reduce the hardness within both the compound and diffusion layers. The effect is completely reversible, and removal of the hydrogen causes the hardness to recover to its original value. The findings show that nitriding is a promising way to control the hydrogen embrittlement of SDSS.     

Hydrogen environment embrittlement of stable austenitic steels

Seven stable austenitic steels (stable with respect to γ → α′ transformation at room temperature) of different alloy compositions (18Cr–12.5Ni, 18Cr–35Ni, 18Cr–8Ni–6Mn–0.25N, 0.6C–23Mn, 1.3C–12Mn, 1C–31Mn–9Al, 18Cr–19Mn–0.8N) were tensile tested in high-pressure hydrogen atmosphere to assess the role of austenite stability on hydrogen environment embrittlement (HEE). The influence of hydrogen on tensile ductility was small in steels that are believed to have a high initial portion of dislocation cross slip (18Cr–12.5Ni, 18Cr–35Ni, 18Cr–8Ni–6Mn–0.25N), while the effects of hydrogen were significantly greater in steels with other primary deformation modes (planar slip in 18Cr–19Mn–0.8N and 1C–31Mn–9Al or mechanical twinning in 0.6C–23Mn and 1.3C–12Mn) despite comparable austenite stability at the given test conditions. It appears that initial deformation mode is one important parameter controlling susceptibility to HEE and that martensitic transformation is not a sufficient explanation for HEE of austenitic steels.     

Hydrogen embrittlement of Cr-Mn-N-austenitic stainless steels

Cr-Mn-N austenitic steels show a unique combination of properties, i.e. high strength, high ductility, non magnetic and good corrosion resistance at costs being much lower compared to Cr-Ni austenitic steels. Hydrogen environment embrittlement (HEE) was investigated by slow displacement tensile testing in hydrogen atmosphere at 10 MPa and −50 °C. The fracture appearance of stable Cr-Mn-N austenitic steels with lower Mn contents (12Mn-0.7N) was transgranular whereas higher Mn contents (18Mn-0.7N) resulted in twin boundary fracture. This change in fracture morphology was related to a modest change in macroscopic ductility. Such fracture behaviour is similar to what is known from metastable Cr-Ni austenitic steels, therefore, Mn and/or N cannot be used to replace Ni in stable austenitic high HEE resistant steels.     

Hydrogen compatibility of austenitic stainless steel tubing and orbital tube welds

Refueling infrastructure for use in gaseous hydrogen powered vehicles requires extensive manifolding for delivering the hydrogen from the stationary fuel storage at the refueling station to the vehicle as well as from the mobile storage on the vehicle to the fuel cell or combustion engine. Manifolds for gas handling often use welded construction (as opposed to compression fittings) to minimize gas leaks. Therefore, it is important to understand the effects of hydrogen on tubing and tubing welds. This paper provides a brief overview of on-going studies on the effects of hydrogen precharging on the tensile properties of austenitic stainless tubing and orbital tube welds.     

Hydrogen diffusivity and tensile-ductility loss of solution-treated austenitic stainless steels with external and internal hydrogen

The effects of external and internal hydrogen on the slow-strain-rate tensile (SSRT) properties at room temperature were studied for ten types of solution-treated austenitic stainless steels containing a small amount of additive elements. The hydrogen diffusivity and solubility of the steels were measured with high-pressure hydrogen gas. The remarkable tensile-ductility loss observed in the SSRT tests was attributed to hydrogen-induced successive crack growth (HISCG) and was successfully quantified according to the nickel-equivalent content (Ni_eq), which represents the stability of the austenitic phase. The relative reduction in area (RRA) of the steels with a larger Ni_eq was influenced by the hydrogen distribution, whereas that of the steels with a smaller Ni_eq was not. This unique trend was interpreted with regard to the hydrogen distribution and fracture morphology (HISCG or microvoid coalescence).     

On the physical differences between tensile testing of type 304 and 316 austenitic stainless steels with internal hydrogen and in external hydrogen

Seventeen metastable austenitic stainless steels (type 304 and 316 alloys) were tested in tension both with internal hydrogen and in external hydrogen. Hydrogen-assisted fracture in both environments is a competition between hydrogen-affected ductile overload and hydrogen-assisted crack propagation. In general, hydrogen localizes the fracture process, which results in crack propagation of particularly susceptible materials at an apparent engineering stress that is less than the tensile strength of the material. Hydrogen-assisted crack propagation in this class of alloys becomes more prevalent at lower nickel content and lower temperature. In addition, for the tests in this study, external hydrogen reduces tensile ductility more than internal hydrogen. External hydrogen promotes crack initiation and propagation at the surface, while with internal hydrogen surface cracking is largely absent, thus preempting hydrogen-assisted crack propagation from the surface. This is not a general result, however, because the reduction of ductility with internal and external hydrogen depends on the specifics of the testing conditions that are compared (e.g., hydrogen gas pressure); in addition, internal hydrogen can promote the formation of internal cracks, which can propagate similar to surface cracks.     

A microstructure informed and mixed-mode cohesive zone approach to simulating hydrogen embrittlement

Hydrogen induced failure under uniaxial tension is simulated in a duplex stainless steel considering microstructural feature of the material. There are three key ingredients in the modelling approach: image processing and finite element representation of the experimentally observed microstructure, stress driven hydrogen diffusion and diffusion coupled cohesive zone modelling of fracture considering mixed failure mode. The microstructure used as basis for the modelling work is obtained from specimens cut in the transverse and longitudinal directions. It is found that the microstructure significantly influences hydrogen diffusion and fracture. The austenite phase is polygonal and randomly distributed in the transverse direction, where a larger effective hydrogen diffusion coefficient and a lower hydrogen fracture resistance is found, compared to the specimen in the longitudinal direction, where the austenite phase is slender and laminated. This indicates that the proper design and control of the austenite phase help improve hydrogen resistance of duplex stainless steel. The strength of the interface in the shear direction is found to dominate the fracture mode and initiation site, which reveals the importance of considering mixed failure mode and calibrating the hydrogen induced strength reduction in shear.     

FE simulation of hydrogen diffusion in duplex stainless steel

ABAQUS FE simulations of hydrogen diffusion in duplex stainless steel have been performed. Three models with different ferrite–austenite configurations have been applied and the hydrogen diffusion and the hydrogen coefficient have been evaluated as a function of austenite phase size and shape and the calculated diffusion coefficients compared to literature. Hydrogen concentration due to stress and plastic strain close to an embedded flaw has also been evaluated. An important observation is that the simulations show that when the austenite phases are saturated with hydrogen there is no large difference in the overall diffusion rate between the small and large phased models, i.e. no influence of tortuosity is observed. The work clearly demonstrates that both microstructure and flaws will influence the hydrogen diffusion and the hydrogen concentration and hence, must be taken into account when evaluating the susceptibility of hydrogen stress cracking in duplex stainless steels.     

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 embrittlement behavior in the nugget zone of friction stir welded X100 pipeline steel

Hydrogen-induced damage is an inevitable challenge in pipeline safety applications, especially, the fusion welded joints owing to microstructure heterogeneity caused by welding process. In this work, X100 pipeline steel was subjected to friction stir welding (FSW) at rotation rates of 300–600 rpm under water cooling, and the relationship among the microstructure, hydrogen diffusivity, and hydrogen embrittlement (HE) behavior of the nugget zone (NZ) were studied. The NZ at 600 rpm had the highest effective hydrogen diffusion coefficient (D_eff) of 2.1 × 10^?10 m²/s because of the highest dislocation density and lowest ratio of effective grain boundary. The D_eff decreased with decreasing rotation rate due to the decrease of dislocation density and the increase of ratio of effective grain boundary, and the lowest D_eff of 1.32 × 10^?10 m²/s was obtained at 300 rpm. After hydrogen charging, the tensile strength of all specimens decreased slightly, while the elongation decreased significantly. As the rotation rate decreased, the elongation loss was obviously inhibited, and ultimately a lowest elongation loss of 31.8% was obtained at 300 rpm. The abovementioned excellent mechanical properties were attributed to the fine ferrite/martensite structure, low D_eff, and strong {111}//ND texture dramatically inhibiting hydrogen-induced cracking initiation and propagation.     

Influence of copper as an alloying element on hydrogen environment embrittlement of austenitic stainless steel

A Cu alloyed (18Cr–10Ni–3Cu) and a Cu free (18Cr–12.7Ni) austenitic stainless steel were tensile tested in gaseous hydrogen atmosphere at 20 °C and −50 °C. Depending on the test temperature, the Cu alloyed steel was extremely embrittled whereas the Cu free steel was only slightly embrittled. Austenite stability and inherent deformation mode are two main criteria for the resistance of austenitic stainless steels against hydrogen environment embrittlement. Based on the well known austenite stability criteria, the austenite stability of both steels should be very similar. Interrupted tensile tests show that martensite formation upon plastic deformation was much more severe in the Cu alloyed steel proving that the influence of Cu on austenite stability is overestimated in the empirical stability equations. When tested in high pressure H₂, replacing Ni by Cu resulted in a fundamental change in fracture mode atmosphere, i.e. Ni cannot be replaced by Cu to reduce the costs of SS without compromising the resistance to hydrogen environment embrittlement.     

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.     

Impact of chemical inhomogeneities on local material properties and hydrogen environment embrittlement in AISI 304L steels

This study investigated the influence of segregations on hydrogen environment embrittlement (HEE) of AISI 304L type austenitic stainless steels. The microstructure of tensile specimens, that were fabricated from commercially available AISI 304L steels and tested by means of small strain-rate tensile tests in air as well as hydrogen gas at room temperature, was investigated by means of combined EDS and EBSD measurements. It was shown that two different austenitic stainless steels having the same nominal alloy composition can exhibit different susceptibilities to HEE due to segregation effects resulting from different production routes (continuous casting/electroslag remelting). Local segregation-related variations of the austenite stability were evaluated by thermodynamic and empirical calculations. The alloying element Ni exhibits pronounced segregation bands parallel to the rolling direction of the material, which strongly influences the local austenite stability. The latter was revealed by generating and evaluating two-dimensional distribution maps for the austenite stability. The formation of deformation-induced martensite was shown to be restricted to segregation bands with a low Ni content. Furthermore, it was shown that the formation of hydrogen induced surface cracks is strongly coupled with the existence of surface regions of low Ni content and accordingly low austenite stability. In addition, the growth behavior of hydrogen-induced cracks was linked to the segregation-related local austenite stability.     

Hydrogen embrittlement characteristics of hot-stamped 22MnB5 steel

Hydrogen embrittlement (HE) characteristics of 22MnB5 steel (U-bent specimen) manufactured using hot-stamping process at various temperatures were experimentally and numerically investigated. Steel resistance to HE was examined through delayed failure tests under static and cyclic loading during hydrogen charging. First, the low cyclic loading caused severe HE, in which a clear difference in the extent of HE was obtained depending on the hot-stamped sample, which directly affected the microstructural characteristics and stress–strain distribution. The hot-stamped samples with large martensite phase showed low resistance to HE compared with those with small martensite phase because of the high concentration of hydrogen trapped in the phase boundaries. Moreover, the dual phase (ferrite and martensite) of the hot-stamped samples reduced their resistance to HE, which is caused by the hydrogen trapped in the laminar-shaped pearlite phase. The resistance to HE was improved by low-temperature heating at 200 °C for 1 h because of the generation of ε-carbides as trap sites as they render the hydrogen non-diffusible. Furthermore, the internal strain in the U-bent sample could accelerate HE because of the high concentration of hydrogen. These results were verified by experimental and numerical analyses. Thus, the hydrogen trapping mechanism was proposed as a valid mechanism for HE in 22MnB5.