Hydrogen-assisted fracture resistance of pipeline welds in gaseous hydrogen

Fracture resistance of pipeline welds from a range of strength grades and welding techniques was measured in air and 21 MPa hydrogen gas, including electric resistance weld of X52, friction stir weld of X100 and gas metal arc welds (GMAW) of X52, X65 and X100. Welds exhibited a decrease in fracture resistance in hydrogen compared to complementary tests in air. A general trend was observed that fracture resistance in 21 MPa hydrogen gas decreased with increasing yield strength. To accommodate material constraints, two different fracture coupon geometries were used in this study, which were shown to yield similar fracture resistance values in air and 21 MPa hydrogen gas; values using different coupons resulted in less than 15% difference. In addition, fracture coupons were removed from controlled locations in select welds to examine the potential influence of orientation and residual stress. The two orientations examined in the X100 GMAW exhibited negligible differences in fracture resistance in air and, similarly, negligible differences in hydrogen. Residual stress exhibited a modest influence on fracture resistance; however, a consistent trend was not observed between tests in air and hydrogen, suggesting further studies are necessary to better understand the influence of residual stress. A comparison of welds and base metals tested in hydrogen gas showed similar susceptibility to hydrogen-assisted fracture. The overall dominant factor in determining the susceptibility to fracture resistance in hydrogen is the yield strength.     

Hydrogen effect on a low carbon ferritic-bainitic pipeline steel

Hydrogen effect on an API 5L X65 low carbon ferritic-bainitic steel is investigated, by evaluating the fracture toughness parameters in air and in hydrogen environment. The hydrogen environment is manifested by in situ hydrogen charging of the X65 steel, using the electrolytic solution NS4, which simulates the electrolyte trapped between the pipeline steel and the coating in a buried pipeline. The fracture toughness results of the X65 are compared to two other pipeline steels with different microstructures, namely an X52 and an X70, possessing a banded ferritic-pearlitic and banded ferritic-mixed bainitic-pearlitic microstructure, respectively. The X65 steel exhibits significant reduction of fracture toughness parameter J₀ integral due to hydrogen charging and insignificant variation of fracture toughness parameter K_Q. Comparing the three steels, the lowest reduction of J₀ integral due to hydrogen charging, is met on the X52 and the highest in the X65.     

Effect of hydrogen on fracture toughness properties of a pipeline steel under simulated sour service conditions

The effect of hydrogen on the fracture toughness properties of an API X65 pipeline steel is studied under simulated H₂S in-service conditions. The fracture toughness properties are measured in LT and SL directions (perpendicular and parallel to the pipeline wall thickness, respectively), following ASTM E1820. Due to size restrictions of standard single edge notch bending (SEB) specimens at the direction parallel to the thickness of the pipeline wall, an experimental protocol (see the patent) was developed to carry out the fracture toughness tests, while complying with ASTM standard 1820. This approach is especially useful in situations where hydrogen induced cracking (HIC) and in a broader sense, stepwise cracking takes place, since these cracks initiate and grow primarily in planes parallel to the pipeline rolling plane. Such values of fracture toughness are often different from those commonly measured in planes perpendicular to the rolling plane. Hydrogen might not have the same effect on fracture toughness properties as measured in different directions, due to microstructural features which are inherent from steel manufacturing process. The steady state H₂S in-service conditions are simulated by electrolytically charging the specimen, for 48 h and then testing (ex-situ) the specimen for evaluating the fracture toughness properties. The steady state H₂S environment charging was obtained by measuring the hydrogen concentration in the bulk of the specimen through thermal desorption spectroscopy (TDS) at three levels of hydrogen concentration. It was observed that the K_Q was moderately decreased with increasing hydrogen concentration in the bulk of the steel, while CTOD₀ showed a significant reduction with increasing hydrogen concentration.     

Predictive environmental hydrogen embrittlement on fracture toughness of commercial ferritic steels with hydrogen-modified fracture strain model

In this work, a practical numerical model with few parameters was proposed for the prediction of environmental hydrogen embrittlement. The proposed method adopts hydrogen enhanced plasticity-based mechanism in a fracture strain model to describe hydrogen embrittlement. Fracture toughness degradation of three commercial steels SA372J70, AISI4130 and X80 in high pressure hydrogen environment were investigated. Firstly, governing equations for hydrogen distribution and material damage evolution was established. Hydrogen enhanced localized flow softening effect was coupled within fracture strain dependency on stress triaxiality. Then, the numerical implementation and identification process of model parameters was described. Model parameters of the investigated steels were determined based on experiment results from literatures. Finally, with the calibrated model, fracture toughness reduction of the steels was predicted in a wide range of hydrogen pressure. The prediction results were compared with experimental results. Reasonable accuracy was reached. The proposed method is an attempt to reach balance between physical accurate prediction and engineering practicality. It is promising to provide a simplified numerical tool for the design and fit for service evaluation of hydrogen storage vessels.     

A systematic study on the influence of electrochemical charging conditions on the hydrogen embrittlement behaviour of a pipeline steel

Although hydrogen embrittlement (HE) has been the subject of extensive research over the past century, a systematic study on the HE susceptibility of steels under different electrochemical charging conditions has been lacking. This study specifically targets this knowledge gap by evaluating the HE behaviour of a typical pipeline steel X65 after hydrogen-charging in acidic, neutral, and alkaline electrolytes that simulate various industrial environments. Results from a series of experiments show that the HE susceptibility of X65 steel varied significantly with hydrogen-charging electrolytes and, to a smaller extent, with electrochemical charging variables. The highest and lowest HE susceptibilities were found from specimens charged in acidic and alkaline electrolytes, respectively. An increase in yield strength was observed for almost all hydrogen-charged specimens, regardless of the charging conditions. Under severe electrochemical charging conditions, blistering was detected and mechanical properties were substantially decreased. Discussion has been made in comprehending these relationships.     

Hydrogen embrittlement of structural steels: Effect of the displacement rate on the fracture toughness of high-pressure hydrogen pre-charged samples

The aim of this paper is to study the effect of the displacement rate on the fracture toughness under internal hydrogen of two different structural steels grades used in energy applications. To this end, steel specimens were pre-charged with gaseous hydrogen at 19.5 MPa and 450 °C for 21 h and then fracture toughness tests were carried out in air at room temperature. Permeation experiments were also conducted to obtain the hydrogen diffusion coefficients of the steels. It was observed that the lower the displacement rate and the higher the steel yield strength, the stronger the reduction in fracture toughness due to the presence of internal hydrogen. A change in the fracture micromechanism was also detected. All these findings were justified in terms of hydrogen diffusion and accumulation in the crack front region in the different steel specimens.     

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.     

A quantitative description on fracture toughness of steels in hydrogen gas

Fracture toughness or critical stress intensity factor of many steels can be reduced by hydrogen gas. In this paper, a simple quantitative model to predict the fracture toughness of steels in gaseous hydrogen is proposed. This model is based on the assumption that fracture of a cracked body occurs when the maximum principal stress ahead of the crack tip reaches the critical cohesive stress for crack initiation. The critical stress is inversely proportional to the accumulated hydrogen concentration. The notion is that the crack will initiate at the elastic-plastic boundary ahead of the crack tip when hydrogen concentration reaches a maximum value after a long-term hydrogen diffusion assisted by the hydrostatic stress. The model describes the dependence of fracture toughness on hydrogen pressure, temperature and yield strength of steels. It can be used to quantitatively predict fracture toughness of steels in hydrogen gas, particularly in high pressure. Some experimental data reported in literature were used to validate the model, and a good agreement was obtained.     

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.     

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.     

Specimen thickness effect on the property of hydrogen embrittlement in single edge notch tension testing of high strength pipeline steel

In the study, hydrogen effects on the fracture toughness of an API X90 pipeline steel are investigated considering specimen thickness effects. It is found that the embrittlement of fracture increases with thickness for the hydrogenated specimens. The fracture toughness of hydrogen-free specimens are about 2.9, 5.2 and 11.6 times larger than the hydrogenated ones for B/W = 0.5, 1 and 2, respectively. Digital image correlation (DIC) measurement indicates that as the specimen thickness increases, hydrogen deteriorates drastically the plasticity in the vicinity of the crack tip. A remarkably low dislocation density is observed, indicating hydrogen atom has great influence on the cohesive energy, rather than the dislocation pile-ups. Finally, it is concluded that hydrogen enhanced decohesion (HEDE) mechanism is responsible for the high hydrogen sensitivity to the specimen thickness.     

Comprehensive study on hydrogen induced cracking of electrical resistance welded API X52 pipeline steel

Different heat treatment cycles were designed in order to investigate the effect of microstructural changes on hydrogen induced cracking resistance (HIC) and mechanical properties of the electric resistance welded steel. The heat treating of the as-welded specimen improved the ductility and impact toughness. After heat treatment, the uniform hardness profile was obtained for the welded specimens. The removal of local hard zones reduced the risk of HIC. The chemical composition and clustering of inclusions have a deleterious effect on cracking resistance in the H₂S environment. Aluminosilicate compounds and MnS inclusions were favorite sites for HIC. The most promising post weld heat treatment for improving mechanical properties and the resistance to HIC was the application of two-cycle quenching followed by tempering.     

Influence of hydrogen content on the tensile properties and fracture of austenitic stainless steel welds

This study evaluates the effects of internal hydrogen on the tensile properties and fracture behaviours of a tungsten inert gas (TIG) weld and an autogenous electron beam (EB) weld of a 304L steel tube. Tensile specimens were thermally charged with hydrogen gas to achieve three different levels of hydrogen in these materials. Metallographic examination revealed that the TIG weld contained skeletal and lathy ferrite, whilst the EB weld displayed a fine dispersion of skeletal and vermicular ferrite. Average volume fractions of ferrite in these welds were 8% and 1%, respectively. The tensile data showed that hydrogen increased the yield and tensile strength, and caused a significant loss in ductility, particularly for the TIG weld. Fractographic analysis revealed that hydrogen induced a change in the fracture mode of the welds and promoted cracking at or near ferrite–austenite interfaces. The TIG weld was found to exhibit a higher susceptibility to hydrogen embrittlement than that of the EB and base metal.     

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 permeation in twinning-induced plasticity (TWIP) steel

The hydrogen permeation behavior of twining-induced plasticity (TWIP) steel was studied using a Devanathan-Stachurski hydrogen permeation cell. The TWIP steel exhibited three orders of magnitude lower hydrogen permeation rate as compared to the mild steel at room temperature. The hydrogen permeation rate of the TWIP steel was 1.71 × 10^?18 mol cm^?1 s^?1 at 25 °C, but it increased with the increase in the electrolyte temperature: 5.55 × 10^?17 mol cm^?1 s^?1 at 30 °C, 6.56 × 10^?17 mol cm^?1 s^?1 at 40 °C and 8.84 × 10^?17 mol cm^?1 s^?1 at 50 °C. Interestingly, the effective hydrogen diffusivity of TWIP steel was significantly higher as compared to that of mild steel, at all the four test temperatures. Activation energy calculations suggest that the hydrogen permeation was primarily through the grain boundaries in TWIP steel, and therefore exhibited higher effective hydrogen diffusivity in comparison with mild steel.     

Ammonia mitigation and induction effects on hydrogen environment embrittlement of SCM440 low-alloy steel

The effect of ammonia (NH₃) contained in hydrogen (H₂) gas on hydrogen environment embrittlement (HEE) of SCM440 low-alloy steel was studied in association with the NH₃ concentration, loading rate, and gas pressure. NH₃ worked as both mitigator of the HEE and inducer of hydrogen embrittlement (HE) depending on the testing conditions. The mitigation of the HEE was achieved by the deactivation of the iron (Fe) surface for H₂ dissociation caused by the preferential adsorption of NH₃ on the Fe surface, which is enhanced by the increase in the NH₃ concentration and decrease in the H₂ gas pressure. NH₃ induced HE was caused due to creating hydrogen by the NH₃ decomposition. Since the NH₃ decomposition rate is low, the induction effect was observed when the loading rate was low. The effect of NH₃ was determined by the competition of the mitigation and induction effects.     

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.     

Influence of hydrogen on the microstructure and fracture toughness of friction stir welded plates of API 5L X80 pipeline steel

In this work, the influence of hydrogen on the microstructure and fracture toughness of API 5L X80 high strength pipeline steel welded by friction stir welding was assessed. Samples were hydrogenated at room temperature for a duration of 10 h in a solution of 0.1 M H₂SO₄ + 10 mg L⁻¹ As₂O₃, with an intensity current of 20 mA cm⁻². Fracture toughness tests were performed at 0 °C in single-edged notched bending samples, using the Critical Crack Tip Opening Displacement (CTOD) parameter. Notches were positioned in different regions within the joint, such as the stir zone, hard zone, and base material. Hydrogen induces internal stress between bainite packets and ferrite plates within bainite packets. Besides, hydrogen acted as a reducer of the strain capacity of the three zones. The base metal had a moderate capacity to resist stable crack growth, displaying a ductile fracture mechanism. While the hard zone showed a brittle behavior with CTOD values below the acceptance limits for pipeline design (0.1–0.2 mm). The fracture toughness of the stir zone is higher than that of the base metal. Nevertheless, the stir zone displayed higher data dispersion due to its high inhomogeneity. Hence, it can also show a brittle behavior with critical CTOD values.     

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.     

Investigation of the hydrogen induced cracking behaviour of API 5L X65 pipeline steel

The effect of microstructural features on the hydrogen induced cracking (HIC) susceptibility of two API 5L X65 pipeline steels were investigated by cathodic charging, hydrogen permeation and hydrogen microprint experiments. Microstructural evaluation after hydrogen charging revealed cracks at the mid-thickness (segregation zone) of both plates. However, more severe cracks were observed in the plate with higher dislocation density and residual stresses. The plate with lower plastic strain and more {111}-oriented grains had less severe cracks. Inclusions found along the crack path, comprising of Si-enriched oxides and carbides contributed to the initiation and propagation of cracks. The variation of the trapping behaviour and hydrogen diffusion through the plates were examined. The results confirmed that a higher ratio of reversible to irreversible traps contributes to increasing HIC severity in steels. Additionally, hydrogen transport through the steels was most prominent along the grain boundaries, indicating the importance of grain boundary character to HIC.