Evaluation of electrochemical hydrogen absorption in welded pipe with steel API X52

The assessment of ability to absorb hydrogen by welds components of API grade pipeline steel X52 has been done. The factors of cathodic hydrogen charging, time of exposure on hydrogen concentration in base metal, heat affected zone and metal of weld were taken into account. It has been shown that all components of weld demonstrate the sensitivity to hydrogenating in deoxygenated, near-neutral pH NS4 solution under relatively “soft” cathodic polarisation, although the efficiency of hydrogen permeation in metal is relatively low and depends on time of exposure. The ability to absorb hydrogen decreases in the following sequence: heat affected zone – base metal – weld. The sensitivity to hydrogenation is higher for heat affected zone in comparison with base metal and weld.     

Optimization of girth welded joint in a high-pressure hydrogen storage tank based on residual stress considerations

The cylinder sections in a high-pressure hydrogen storage tank are usually connected by girth welded joints. However, due to the ultra-thick wall of the cylinder, the weld geometry has a significant influence on the residual stress distributions, which are very difficult to be fully determined by experimental methods. Therefore, in this paper, four sequential coupling two-dimensional (2D) axisymmetric finite element (FE) models with different weld geometries have been developed to study the effects of weld groove shape on the residual stresses. In addition, the effects of working pressure (75 MPa) on the welding residual stress distributions have been investigated. The results demonstrate that different weld groove shapes bring different residual stress distributions, leading to different influences on structural integrity. Among the four types of welded joints, V and U types have similar residual stress distributions, and X and d-U types have similar distributions, but the latter two types have large tensile residual stresses at their inner surfaces, which have a greater risk of generating hydrogen induced cracking (HIC). After introducing a working pressure of 75 MPa, the welding residual stresses are redistributed, and the weld regions of the four types of welded joints are all fully yielded and plasticized. Based on the residual stress considerations, using V-shape groove can obtain the best residual stress distributions in an ultra-thick girth welded joint, which provides a reference for the welding and fabrication of a high-pressure hydrogen storage tank.     

Static and impact crack properties of a high-strength steel welded joint

In order to gain the benefits of weldable high-strength steels in pressurized equipment applications, satisfactory toughness and crack properties of the welded joint, both in the weld metal and the heat-affected –zone (HAZ), are required. Experimental investigations of toughness and crack resistance parameters through static and impact tests of a high-strength, low-alloy steel (HSLA) with a nominal yield strength of 700 MPa and its welded joint, were performed on Charpy-sized specimens, V-notched and pre-cracked, of the parent metal, weld metal and HAZ. The selected electrode produced slight undermatching and enabled the welded joints to be manufactured without cold cracks. The impact energy and its parts responsible for crack initiation and propagation were determined by toughness evaluation. Crack sensitivity, defined as the ratio of the impact energy for V-notched and for pre-cracked specimens, enabled a comparison of the homogeneous microstructure of the parent metal and the weld metal, and of the heterogeneous microstructure of the heat-affected-zone (HAZ), which indicated a better crack toughness behaviour of the HAZ. The results obtained showed that the toughness and crack resistance of the weld metal were significantly lower than those of the parent metal and the HAZ. The fracture mechanics parameters, J_Ic integral, and plane strain fracture toughness, K_Ic, as well as J resistance curves expressed the degradation less.     

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.     

Evaluation of creep damage in heat affected zone of thick welded joint for Mod.9Cr–1Mo steel

Mod.9Cr–1Mo steel has been used for boiler components in ultra-supercritical (USC) thermal power plants. The creep strength of welded joint of this steel decreases due to the formation of Type IV cracking in heat affected zone (HAZ) at higher temperatures. The present paper aims to clarify the damage processes and mechanisms of the welded joint for Mod.9Cr–1Mo steel. Long-term creep tests of base metal, welded joint and simulated fine- grained HAZ were conducted at 550, 600 and 650 °C. Creep tests using thick plate welded joint specimen were interrupted at several time steps, and evolutions and distributions of creep damages were measured quantitatively using laser microscope. It is found that creep voids initiate at early stage of creep life (0.2 of life), the number of creep voids increases until 0.7 of life, and then voids coalesced into the macro crack at the later stage of life (0.8 of life). Creep damages concentrate mostly at a quarter depths of the plate thickness within the fine-grained HAZ of the present welded joint. The experimental creep damage distributions were compared with the computed results by using the FEM analysis. Both creep strain concentration and high stress triaxiality in fine-grained HAZ of welded joint are considered to accelerate the creep void formation and growth.     

Effects of geometry and combined loading on steady-state creep stresses in welded branches

In our previous paper, it was found that the mis-match effect in creep on steady-state stresses within the weld metal for a large bore branch junction could be uniquely quantified by the mis-match factor defined as a function of the creep stress exponent and the ratio of creep constants for the base and weld materials. Furthermore ratios of section-averaged (effective and maximum principal) stresses for the mis-matched case to those for the even-matched case were linearly dependent on the mis-match factor. Above results were obtained for a specific branch geometry under single loading. This paper extends our previous analysis to other branch geometries and to combined loading. It is found that above conclusions can be applied to general branch components under combined loading.     

Spatial variation of residual stresses in a welded pipe for high temperature applications

Measurements of residual macro-stresses have been undertaken in a feature multipass circumferential single V butt-weld made from a P91 ferritic steel pipe over different spatial depths: (i) ≤10 μm by X-ray diffraction, (ii) ≤1 mm by incremental centre-hole drilling and (iii) through wall section using deep-hole drilling. The ability to make near-surface X-ray residual stress measurements on as-oxidised surfaces has been demonstrated and the implications for use in the evaluation of overall integrity are discussed. Each of the three measurement techniques provides complementary and consistent measurement of induced residual stresses for weld metal, heat affected zone and parent metal for the as-welded and the post-weld heat-treated conditions over the complete spatial range. The results are discussed with respect to the importance of the weld capping run in introducing near-surface compressive residual stresses, the through-wall profiles of the residual stresses measured at the weld metal position in hoop and axial directions and the presence of existing surface oxide.     

Predictions and measurements of residual stress in repair welds in plates

This paper presents the work, from the European Union FP-5 project ELIXIR, on a series of rectangular repair welds in P275 and S690 steels to validate the numerical modelling techniques used in the determination of the residual stresses generated during the repair process. The plates were 1,000 mm by 800 mm with thicknesses of 50 and 100 mm. The repair welds were 50%, 75% and 100% through the plate thickness. The repair welds were modelled using the finite element method to make predictions of the as-welded residual stress distributions. These predictions were compared with surface-strain measurements made on the parent plates during welding and found to be in good agreement. Through-thickness residual stress measurements were obtained from the test plates through, and local to, the weld repairs using the deep hole drilling technique. Comparisons between the measurements and the finite element predictions generally showed good agreement, thus providing confidence in the method.     

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.     

Residual stresses in the welding joint of the nozzle-to-head area of a layered high-pressure hydrogen storage tank

In this study, a sequentially coupling finite element analysis (FEA) program was utilized to simulate the welding temperature and predict the residual stress in the weld and Heat Affect Zone (HAZ) between the nozzle and the head. The results of a numerical calculation indicated that complex residual stresses were generated and concentrated in the weld and HAZ. Due to the existence of the interlayer gap between the two layers of the head, discontinuous stress distributions occurred. There were several sections where there are stress concentrations because of the discontinuous structure. The influences of welding heat input and preheating temperature were also investigated in this study. When the preheating temperature increased, the peak residual stresses in the structure decreased. The welding heat input had little effect on the residual stresses.     

Optimization of welding joint between tower and bottom flange based on residual stress considerations in a wind turbine

In this study, a geometry optimization of welding joint between tower and bottom flange in a wind turbine is performed based on residual stress considerations. A sequentially coupling finite element analysis (FEA) program is developed to simulate the welding temperature and residual stress. Using this FEA program, four FE models with different bevel are developed to calculate their residual stresses, which are compared to optimize the weld geometry. The results show that complex residual stresses are generated and concentrated in the fillet weld. Using K type bevel with internal concave fillet and outside convex fillet can obtain the minimal residual stress, which provides a reference the fabrication of wind turbines.     

Compression properties of gas diffusion layers and its constitutive model under cyclic loading

The compressive deformation of gas diffusion layer (GDL), which is highly nonlinear and related to the loading history, affects the performance of PEM fuel cell stacks. However, linear elastic models are widely used. In this study, a new nonlinear constitutive model is proposed to describe the compression properties. Macroscopic studies reveal that GDL has different mechanical properties during the first and repeated compression stages. Besides, the tangent modulus has a significant linear relationship with stress. The constitutive model can be rebuilt using the micro-mechanical theory of fiber assemblies by considering the bending of carbon fibers. Furthermore, a prediction method is proposed to describe cyclic compression behavior. The prediction results fit well with the test results with an average and maximum relative error of less than 5.30% and 18.13%, respectively. These conclusions are beneficial to the design of GDL with specific mechanical properties and the real-time analysis of PEM fuel cell.     

Measuring and modelling residual stresses in butt welded P91 steel pipe including effects of phase transformations

Abstract

Residual stresses in a circumferentially butt welded steel pipe have been measured and numerically predicted. The pipe, containing the circumferential weld, has an outer diameter of 290 mm and a wall thickness of 55 mm, typical of components in power generation plants. An axisymmetric thermomechanical finite element (FE) simulation has been performed to obtain the residual stress field induced by the fusion welding of the pipe, taking solid state phase transformation effects into account and using temperature dependent material property data. Residual stresses have been measured using the X-ray diffraction and deep hole drilling techniques. Good correlation has been demonstrated with the predictions of the FE model. The paper demonstrates that a mixed experimental and numerical approach is useful for determining the residual stress distribution in welded joints.     

Effect of vibratory weld conditioning on the residual stresses and distortion in multipass girth-butt welded pipes

For a fully welded body valve, the last procedure is welding, so it is important to control the residual stress and distortion in order to assure spool rotation, valve watertightness, stress corrosion resistance and non-deformability in active service. In this study, the effects of vibratory weld conditioning (VWC) on the residual stress and distortion were studied in multipass girth-butt welded pipes through comparison between VWC and normal submerged arc welding. The results show that VWC can reduce the residual hoop stresses at the outer surface and the radial distortion significantly; but VWC has only a slight effect on the residual axial stresses at the outer surface and axial distortion. Moreover, the residual stresses decrease and are lower than the yield strength using VWC, which decreases the susceptibility of a weld to fatigue damage, stress corrosion cracking and fracture, and improves the safety of welded structures.     

热管和内螺纹管在低温空气预热器中的应用

结合目前低温空气预热器存在的问题和实际应用的结果，通过对光管、内螺纹管和热管的传热，流动阻力以及壁温（低温腐蚀）性能进行对比分析，阐述了内螺纹管和热管换热器作为空气预热器的优点，并说明了它们的适用条件。     

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.     

Length scale of secondary stresses in fracture and fatigue

In an attempt to provide a consistent framework for the analysis and treatment of secondary stresses associated with welding and thermal loading in the context of fracture mechanics, this paper starts with an effective stress characterization procedure by introducing a length-scale concept. With it, a traction-based stress separation procedure is then presented to provide a consistent characterization of stresses from various sources based on their length scale. Their relative contributions to fracture driving force are then quantified in terms of their characteristic length scales. Special attention is given to the implications of the length-scale argument on both analysis and treatment of welding residual stresses in fracture assessment. A series of examples is provided to demonstrate how the present developments can be applied for treating not only secondary stresses but also externally applied stresses, as well as their combined effects on the structural integrity of engineering components.     

Effective thermal conductivity and thermal contact resistance of gas diffusion layers in proton exchange membrane fuel cells. Part 2: Hysteresis effect under cyclic compressive load

Heat transfer through the gas diffusion layer (GDL) is a key process in the design and operation of a PEM fuel cell. The analysis of this process requires the determination of the effective thermal conductivity as well as the thermal contact resistance between the GDL and adjacent surfaces/layers. The Part 1 companion paper describes an experimental procedure and a test bed devised to allow separation of the effective thermal conductivity and thermal contact resistance, and presents measurements under a range of static compressive loads. In practice, during operation of a fuel cell stack, the compressive load on the GDL changes.In the present study, experiments are performed on Toray carbon papers with 78% porosity and 5% PTFE under a cyclic compressive load. Results show a significant hysteresis in the loading and unloading cycle data for total thermal resistance, thermal contact resistance (TCR), effective thermal conductivity, thickness, and porosity. It is found that after 5 loading-unloading cycles, the geometrical, mechanical, and thermal parameters reach a “steady-state” condition and remain unchanged. A key finding of this study is that the TCR is the dominant component of the GDL total thermal resistance with a significant hysteresis resulting in up to a 34% difference between the loading and unloading cycle data. This work aims to clarify the impact of unsteady/cyclic compression on the thermal and structural properties of GDLs and provides new insights on the importance of TCR which is a critical interfacial transport phenomenon.     

Residual stress and plastic strain analysis in the brazed joint of bonded compliant seal design in planar solid oxide fuel cell

This paper uses finite element method (FEM) to predict the residual stress and plastic strain in the brazed joint of sealing foil-to-window frame in bonded compliant seal (BCS) design in a planar solid oxide fuel cell (PSOFC). The effects of window frame material type, sealing foil thickness, filler metal thickness and window frame thickness on residual stress and plastic strain are discussed. Large residual stress is generated in the joint, and the stress and strain are concentrated around the fillet. It is proved that the BCS design can mitigate and trap some residual stress by plastic deformation within the sealing foil. The residual stress and the ability of trapping stress of sealing foil are affected by window frame material and structure thickness. Based on the comprehensive considerations of the impact of residual stress and plastic strain, Alloy 625 as a window frame material is found to be better than Haynes 214, Hastelloy X and SUS 316L. The optimum thickness of sealing foil and filler metal BNi2 are found to be 150 μm and 75 μm, respectively. The residual stress and plastic strain are increased with the increase of window frame thickness.     

Finite element analysis of metallurgical phase transformations in AA 6056-T4 and their effects upon the residual stress and distortion states of a laser welded T-joint

Aircraft industry makes extensive use of aluminium alloy AA 6056-T4 in the fabrication of fuselage panels using laser beam welding technique. Since high temperatures are involved in the manufacturing process, the precipitation/dissolution occurrences are expected as solid state phase transformations. These transformations are likely to affect the residual distortion and stress states of the component. The present work investigates the effect of metallurgical phase transformations upon the residual stresses and distortions induced by laser beam welding in a T-joint configuration using the finite element method. Two separate models were studied using different finite element codes, where the first one describes a thermo-mechanical analysis using Abaqus; while the second one discusses a thermo-metallo-mechanical analysis using Sysweld. A comparative analysis of experimentally validated finite element models has been performed and the residual stress states with and without the metallurgical phase transformations are predicted. The results show that the inclusion of phase transformations has a negligible effect on predicted distortions, which are in agreement with the experimental data, but an effect on predicted residual stresses, although the experimentally measured residual stresses are not available to support the analyses.