This study investigates the fatigue crack growth rate (FCGR) behavior of pipeline and low-alloy pressure vessel steels in high-pressure gaseous hydrogen. Despite a broad range of yield strengths and microstructures ranging from ferrite/pearlite, acicular ferrite, bainite, and martensite, the FCGR in gaseous hydrogen remained consistent (falling within a factor of 2–3). Steels with higher fractions of pearlite, typical of older vintage pipeline steels, exhibited modestly lower crack growth rates in gaseous hydrogen compared to steels with lower fractions of pearlite. Crack growth rates in these materials exhibit a systematic dependence on stress ratio and partial pressure of hydrogen, as captured in the recently published fatigue design curves in ASME B31 code case 220 for pipeline steels and ASME BPVC code case 2938 for pressure-vessel steels.
Welding processes used in the production of pressure vessels impart residual stresses in the manufactured component. Computational modeling is critical to predicting these residual stress fields and understanding how they interact with notches and flaws to impact pressure vessel durability. Here, in this work, we present a finite element model for a resistance forge weld and validate it using laboratory measurements. Extensive microstructural changes, near-melt temperatures, and large localized deformations along the weld interface pose significant challenges to Lagrangian finite element modeling. The proposed modeling approach overcomes these roadblocks in order to provide a high-fidelity simulation that can predict the residual stress state in the manufactured pressure vessel; a rich microstructural constitutive model accounts for material recrystallization dynamics, a frictional-to-tied contact model is coordinated with the constitutive model to represent interfacial bonding, and adaptive remeshing is employed to alleviate severe mesh distortion. An interrupted-weld approach is applied to the simulation to facilitate comparison to displacement measures. Several techniques are employed for residual stress measurement in order to validate the finite element model: neutron diffraction, the contour method, and the slitting method. Model-measurement comparisons are supplemented with detailed simulations that reflect the configurations of the residual-stress measurement processes themselves. The model results show general agreement with experimental measurements, and we observe some similarities in the features around the weld region. Factors that contribute to model-measurement differences are identified. Finally, we conclude with some discussion of the model development and residual stress measurement strategies, including how to best leverage the efforts put forth here for other weld problems.
Hydrogen is known to embrittle austenitic stainless steels, which are widely used in high-pressure hydrogen storage and delivery systems, but the mechanisms that lead to such material degradation are still being elucidated. The current work investigates the deformation behavior of single crystal austenitic stainless steel 316L through combined uniaxial tensile testing, characterization and atomistic simulations. Thermally precharged hydrogen is shown to increase the critical resolved shear stress (CRSS) without previously reported deviations from Schmid's law. Molecular dynamics simulations further expose the statistical nature of the hydrogen and vacancy contributions to the CRSS in the presence of alloying. Slip distribution quantification over large in-plane distances (>1 mm), achieved via atomic force microscopy (AFM), highlights the role of hydrogen increasing the degree of slip localization in both single and multiple slip configurations. The most active slip bands accumulate significantly more deformation in hydrogen precharged specimens, with potential implications for damage nucleation. For 〈110〉 tensile loading, slip localization further enhances the activity of secondary slip, increases the density of geometrically necessary dislocations and leads to a distinct lattice rotation behavior compared to hydrogen-free specimens, as evidenced by electron backscatter diffraction (EBSD) maps. The results of this study provide a more comprehensive picture of the deformation aspect of hydrogen embrittlement in austenitic stainless steels.
Existing natural gas (NG) pipeline infrastructure can be used to transport gaseous hydrogen (GH2) or blends of NG and hydrogen as low carbon alternatives to NG. Pipeline steels exhibit accelerated fatigue crack growth rates and reduced fracture resistance in the presence of GH2. The hydrogen-assisted fatigue crack growth (HAFCG) rates and hydrogen assisted fracture (HAF) resistance for pipeline steels depend on the hydrogen gas pressure. This study aims to correlate and compare the HAFCG rates of pipeline steels tested in two different gaseous environments at different pressures; high-purity hydrogen (99.9999 % H2) and a blend of nitrogen with 3% hydrogen gas (N2+3%H2). K-controlled FCG tests were performed using compact tension (CT) samples extracted from a vintage X52 (installed in 1962) and a modern X70 (2021) pipeline steel in the different gaseous environments. Subsequently, monotonic fracture tests were performed in the GH2 environment. The HAFCG rates increased with increasing GH2 pressure for both steels, in the ΔK range explored in this study. Nearly identical HAFCG rates were observed for the steels tested in different environments with equivalent fugacity (34.5 bar pure GH2 and 731 bar Blend with 3%H2). The fracture resistance of pipeline steels was significantly reduced in the presence of GH2, even at pressure as low as 1 bar. The reduction in HAF resistance tends to saturate with increasing GH2 pressure. While the fracture resistance of modern steel is substantially higher than vintage steel in air, in high pressure GH2, the HAF resistance is comparable. Similar HAF resistance values were obtained for the respective steels in the pure and blended GH2 environment with similar fugacity. This study confirms that fugacity parameter can be used to correlate HAFCG and HAF behavior of different hydrogen blends. The fracture surface features of the pipeline steels, tested in the different environments are compared to rationalize the observed behavior in GH2.
Full-scale testing of pipes is costly and requires significant infrastructure investments. Subscale testing offers the potential to substantially reduce experimental costs and provides testing flexibility when transferrable test conditions and specimens can be established. To this end, a subscale pipe testing platform was developed to pressure cycle 60 mm diameter pipes (Nominal Pipe Size 2) to failure with gaseous hydrogen. Engineered defects were machined into the inner surface or outer surface to represent pre-existing flaws. The pipes were pressure cycled to failure with gaseous hydrogen at pressures to match operating stresses in large diameter pipes (e.g., stresses comparable to similar fractions of the specified minimum yield stress in transmission pipelines). Additionally, the pipe specimens were instrumented to identify crack initiation, such that crack growth could be compared to fracture mechanics predictions. Predictions leverage an extensive body of materials testing in gaseous hydrogen (e.g., ASME B31.12 Code Case 220) and the recently developed probabilistic fracture mechanics framework for hydrogen (Hydrogen Extremely Low Probability of Rupture, HELPR). In this work, we evaluate the failure response of these subscale pipe specimens and assess the conservatism of fracture mechanics-based design strategies (e.g., API 579/ASME FFS). This paper describes the subscale hydrogen testing capability, compares experimental outcomes to predictions from the probabilistic hydrogen fracture framework (HELPR), and discusses the complement to full-scale testing.
Structural materials used in combustion or power generation systems need to have both environmental and temperature resistance to ensure long-term performance. As the energy sector transitions to hydrogen, there is a need to ensure compatibility of highly-alloyed austenitic steels and nickel-based alloys with hydrogen over a range of temperatures. Hydrogen embrittlement of these alloy systems is often considered most detrimental near ambient temperatures and low temperatures, although there is some evidence in the literature that hydrogen can affect creep behavior at elevated temperature. In the intermediate temperature range (e.g., 100-400C), it is uncertain whether hydrogen degradation of mechanical properties will be of concern. In this study, three alloys (304L, IN625, Hastelloy X) commonly used in power generation systems were thermally precharged with hydrogen and subsequently tensile tested to failure in air at temperatures ranging from 20°C to 200°C. At 20°C, the hydrogen-precharged condition for all materials exhibited loss in ductility with relative reduction of area ranging between 32% and 57%. The three alloys exhibited different trends with temperature but, in general, the relative reduction of area improved with increasing temperature tending towards noncharged behavior. Tests were performed at a nominal strain rate of 2 x 10-3 s-1 in order to minimize loss of hydrogen during elevated temperature testing. Hydrogen contents from the grip sections were measured both before and after testing and remained within 10% of starting content for 100°C tests and within 8-23% for 200°C tests.
Natural gas pipelines could be an important pathway to transport gaseous hydrogen (GH2) as a cleaner alternative to fossil fuels. However, a comprehensive understanding of hydrogen-assisted fatigue and fracture resistance in pipeline steels is needed, including an assessment of the diverse microstructures present in natural gas infrastructure. In thus study, we focus on modern steel pipe and consider both welded pipe and seamless pipe. In-situ fatigue crack growth (FCG) and fracture tests were conducted on compact tension samples extracted from the base metal, seam-weld, and heat affected zone of an X70 pipe steel in high-purity GH2 (210 bar pressure). Additionally, a seamless X65 pipeline microstructure (with comparable strength) was evaluated to compare the different microstructure of seamless pipe. The different microstructures had comparable FCG rates in GH2, with crack growth rates up to 30 times faster in hydrogen compared to air. In contrast, the fracture resistance in GH2 depended on the characteristics of the microstructure varying in the range of approximately 80 to 110 MPa√m.
Gaseous hydrogen is known to embrittle most steels, including the steels used in natural gas pipelines. As injection of hydrogen into the existing natural gas infrastructure is considered globally by the pipeline industry, the structural integrity of pipelines transporting gaseous hydrogen must be investigated. Hydrogen Extremely Low Probability of Rupture (HELPR) is a publicly available and open-source probabilistic fatigue and fracture mechanics toolkit recently developed at Sandia National Laboratories. HELPR is intended to incorporate the influence of hydrogen into structural integrity assessments of natural gas transmission and distribution infrastructure. HELPR utilizes engineering models, such as those specified in ASME B31.12 and API 579, with relatively low computational costs to perform large sample ensembles, enabling estimation of performance distributions including low probability tail estimates. Leveraging the probabilistic capabilities built into HELPR, the sensitivity of fatigue and fracture calculations to specific modeling parameters on performance margins can be quantified. Through applying HELPR’s probabilistic capabilities to realistic scenarios, the impact of uncertainty in specific model parameter descriptions on performance margins, such as cycles to unstable crack growth or rupture in gaseous hydrogen, can be characterized; this same approach can then be used to assess the impact of reducing uncertainty sources on the resulting performance metrics, margins, and associated risks. A few industry-motivated scenarios are used to demonstrate this approach.
To decarbonize the energy sector, there are international efforts to displace carbon-based fuels with renewable alternatives, such as hydrogen. Storage and transportation of gaseous hydrogen are key components of large-scale deployment of carbon-neutral energy technologies, especially storage at scale and transportation over long distances. Due to the high cost of deploying large-scale infrastructure, the existing pipeline network is a potential means of transporting blended natural gas-hydrogen fuels in the near term and carbon-free hydrogen in the future. Much of the existing infrastructure in North America was deployed prior to 1970 when greater variability existed in steel processing and joining techniques often leading to microstructural inhomogeneities and hard spots, which are local regions of elevated hardness relative to the pipe or weld. Hard spots, particularly in older pipes and welds, are a known threat to structural integrity in the presence of hydrogen. High-strength materials are susceptible to hydrogen-assisted fracture, but the susceptibility of hard spots in otherwise low-strength materials (such as vintage pipelines) has not been systematically examined. Assessment of fracture performance of pipeline steels in gaseous hydrogen is a necessary step to establish an approach for structural integrity assessment of pipeline infrastructure for hydrogen service. This approach must include comprehensive understanding of microstructural anomalies (such as hard spots), especially in vintage materials. In this study, fracture resistance of pipeline steels is measured in gaseous hydrogen with a focus on high strength materials and hardness limits established in common practice and in current pipeline codes (such as ASME B31.12). Elastic-plastic fracture toughness measurements were compared for several steel grades to identify the relationship between hardness and fracture resistance in gaseous hydrogen.
Emerging hydrogen technologies span a diverse range of operating environments. High-pressure storage for mobility applications has become commonplace up to about 1,000 bar, whereas transmission of gaseous hydrogen can occur at hydrogen partial pressure of a few bar when blended into natural gas. In the former case, cascade storage is utilized to manage hydrogen-assisted fatigue and the Boiler and Pressure Vessel Code, Section VIII, Division 3 includes fatigue design curves for fracture mechanics design of hydrogen vessels at pressure of 1,030 bar (using a Paris Law formulation). Recent research on hydrogen-assisted fatigue crack growth has shown that a diverse range of ferritic steels show similar fatigue crack growth behavior in gaseous hydrogen environments, including low-carbon steels (e.g., pipeline steels) as well as quench and tempered Cr-Mo and Ni-Cr-Mo pressure vessel steels with tensile strength less than 915 MPa. However, measured fatigue crack growth is sensitive to hydrogen partial pressure and fatigue crack growth can be accelerated in hydrogen at pressure as low as 1 bar. The effect of hydrogen partial pressure from 1 to 1,000 bar can be quantified through a simple semi-empirical correction factor to the fatigue crack growth design curves. This paper documents the technical basis for the pressure-sensitive fatigue crack growth rules for gaseous hydrogen service in ASME B31.12 Code Case 220 and for revision of ASME VIII-3 Code Case 2938-1, including the range of applicability of these fatigue design curves in terms of environmental, materials and mechanics variables.
Decarbonization efforts highlight hydrogen as an attractive alternative to fossil fuels, but its tendency to embrittle structural metals demands careful consideration when designing hydrogen infrastructure. Moreover, the mechanisms by which hydrogen degrades these materials are still being elucidated. The current work develops new computational tools to quantify the different contributions of hydrogen to the energy barrier of cross-slip, a key deformation mechanism. Novel features are implemented to a line tension model, which include the use of non-singular dislocation interactions, character-dependent dislocation energies and simulations of the constriction configurations. A new molecular dynamics technique is developed to calculate the interaction energy between the partials of a dissociated dislocation via fixing the centers of mass of the regions below and above the Shockley partials and performing time-averaged calculations. Hydrogen is found to impact the stacking fault width of dislocations in different ways depending on their characters: it decreases for dislocations with a character θ > 30°, remains unchanged for θ = 30° and increases for θ < 30°. The latter regime is a newly identified mechanism by which hydrogen inhibits cross-slip. Moreover, formation of nano-hydrides is predicted to occur around screw dislocations for high hydrogen concentrations, a phenomenon previously identified only in dislocations with an edge component. If nano-hydrides develop, their influence extending the equilibrium stacking fault width and increasing both the constriction and cross-slip energy barriers dominate over all other hydrogen contributions. The theory and tools developed will pave the way towards a comprehensive understanding of hydrogen-dislocation interactions in structural metals.