Publications

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In this work, we investigate the potential of liquid hydrogen storage (LH₂) on-board Class-8 heavy duty trucks to resolve many of the range, weight, volume, refueling time and cost issues associated with 350 or 700-bar compressed H₂ storage in Type-3 or Type-4 composite tanks. We present and discuss conceptual storage system configurations capable of supplying H₂ to fuel cells at 5-bar with or without on-board LH₂ pumps. Structural aspects of storing LH₂ in double walled, vacuum insulated, and low-pressure Type-1 tanks are investigated. Structural materials and insulation methods are discussed for service at cryogenic temperatures and mitigation of heat leak to prevent LH₂ boiloff. Failure modes of the liner and shell are identified and analyzed using the regulatory codes and detailed finite element (FE) methods. The conceptual systems are subjected to a Failure modes and effects analysis (FMEA) and a safety, codes, and standards (SCS) review to rank failures and identify safety gaps. The results indicate that the conceptual systems can reach 19.6% usable gravimetric capacity, 40.9 g-H₂/L usable volumetric capacity and $174-183/kg-H₂ cost (2016 USD) when manufactured 100,000 systems annually.

Austenitic stainless steels have been extensively tested in hydrogen environments; however, limited information exists for the effects of hydrogen on the fatigue life of high-strength grades of austenitic stainless steels. Moreover, fatigue life testing of finished product forms (such as tubing and welds) is challenging. A novel test method for evaluating the influence of internal hydrogen on fatigue of orbital tube welds was reported, where a cross hole in a tubing specimen is used to establish a stress concentration analogous to circumferentially notched bar fatigue specimens for constant-load, axial fatigue testing. In that study (Kagay et al, ASME PVP2020-8576), annealed 316L tubing with a cross hole displayed similar fatigue performance as more conventional materials test specimens. A similar cross-hole tubing geometry is adopted here to evaluate the fatigue crack initiation and fatigue life of XM-19 austenitic stainless steel with high concentration of internal hydrogen. XM-19 is a nitrogen-strengthened Fe-Cr-Ni-Mn austenitic stainless steel that offers higher strength than conventional 3XX series stainless steels. A uniform hydrogen concentration in the test specimen is achieved by thermal precharging (exposure to high-pressure hydrogen at elevated temperature for two weeks) prior to testing in air to simulate the equilibrium hydrogen concentration near a stress concentration in gaseous hydrogen service. Specimens are also instrumented for direct current potential difference measurements to identify crack initiation. After accounting for the strengthening associated with thermal precharging, the fatigue crack initiation and fatigue life of XM-19 tubing were virtually unchanged by internal hydrogen.

Austenitic stainless steels have been extensively tested in hydrogen environments; however, limited information exists for the effects of hydrogen on the fatigue life of high-strength grades of austenitic stainless steels. Moreover, fatigue life testing of finished product forms (such as tubing and welds) is challenging. A novel test method for evaluating the influence of internal hydrogen on fatigue of orbital tube welds was reported, where a cross hole in a tubing specimen is used to establish a stress concentration analogous to circumferentially notched bar fatigue specimens for constant-load, axial fatigue testing. In that study (Kagay et al, ASME PVP2020-8576), annealed 316L tubing with a cross hole displayed similar fatigue performance as more conventional materials test specimens. A similar cross-hole tubing geometry is adopted here to evaluate the fatigue crack initiation and fatigue life of XM-19 austenitic stainless steel with high concentration of internal hydrogen. XM-19 is a nitrogen-strengthened Fe-Cr-Ni-Mn austenitic stainless steel that offers higher strength than conventional 3XX series stainless steels. A uniform hydrogen concentration in the test specimen is achieved by thermal precharging (exposure to high-pressure hydrogen at elevated temperature for two weeks) prior to testing in air to simulate the equilibrium hydrogen concentration near a stress concentration in gaseous hydrogen service. Specimens are also instrumented for direct current potential difference measurements to identify crack initiation. After accounting for the strengthening associated with thermal precharging, the fatigue crack initiation and fatigue life of XM-19 tubing were virtually unchanged by internal hydrogen.

Austenitic stainless steels are used in high-pressure hydrogen containment infrastructure for their resistance to hydrogen embrittlement. Applications for the use of austenitic stainless steels include pressure vessels, tubing, piping, valves, fittings and other piping components. Despite their resistance to brittle behavior in the presence of hydrogen, austenitic stainless steels can exhibit degraded fracture performance. The mechanisms of hydrogen-assisted fracture, however, remain elusive, which has motivated continued research on these alloys. There are two principal approaches to evaluate the influence of gaseous hydrogen on mechanical properties: internal and external hydrogen, respectively. The austenite phase has high solubility and low diffusivity of hydrogen at room temperature, which enables introduction of hydrogen into the material through thermal precharging at elevated temperature and pressure; a condition referred to as internal hydrogen. H-precharged material can subsequently be tested in ambient conditions. Alternatively, mechanical testing can be performed while test coupons are immersed in gaseous hydrogen thereby evaluating the effects of external hydrogen on property degradation. The slow diffusivity of hydrogen in austenite at room temperature can often be a limiting factor in external hydrogen tests and may not properly characterize lower bound fracture behavior in components exposed to hydrogen for long time periods. In this study, the differences between internal and external hydrogen environments are evaluated in the context of fracture resistance measurements. Fracture testing was performed on two different forged austenitic stainless steel alloys (304L and XM-11) in three different environments: 1) non-charged and tested in gaseous hydrogen at pressure of 1,000 bar (external H2), 2) hydrogen precharged and tested in air (internal H), 3) hydrogen precharged and tested in 1,000 bar H2 (internal H + external H2). For all environments, elastic-plastic fracture measurements were conducted to establish J-R curves following the methods of ASTM E1820. Following fracture testing, fracture surfaces were examined to reveal predominant fracture mechanisms for the different conditions and to characterize differences (and similarities) in the macroscale fracture processes associated with these environmental conditions.

There is a global interest in decarbonizing the existing natural gas infrastructure by blending the natural gas with hydrogen. However, hydrogen is known to embrittle pipeline and pressure vessel steels used in gas transportation and storage applications. Thus, assessing the structural integrity of vintage pipeline (pre-1970s) in the presence of gaseous hydrogen is a critical step towards successful implementation of hydrogen blending into existing infrastructure. To this end, fatigue crack growth (FCG) behavior and fracture resistance of several vintage X52 pipeline steels were evaluated in high purity gaseous hydrogen environments at pressure of 210 bar (3,000 psi) and 34 bar (500 psi). The base metal and seam weld microstructures were characterized using optical microscopy, scanning electron microscopy (SEM) and Vickers hardness mapping. The base metals consisted of ferrite-pearlite banded microstructures, whereas the weld regions contained ferrite and martensite. In one case, a hook-like crack was observed in an electric resistance (seam) weld; whereas hard spots were observed near the bond line of a double-submerged arc (seam) weld. For a given hydrogen gas pressure, comparable FCG rates were observed for the different base metal and weld microstructures. Generally, the higher strength microstructures had lower fracture resistance in hydrogen. In particular, lower fracture resistance was measured when local hard spots were observed in the approximate region of the crack plane of the weld. Samples tested in lower H2 pressure (34 bar) exhibited lower FCG rates (in the lower ∆K regime) and greater fracture resistance when compared to the respective high-pressure (210 bar) hydrogen tests. The hydrogen-assisted fatigue and fracture surfaces were qualitatively characterized using SEM to rationalize the influence of microstructure on the dominant fracture mechanisms in gaseous hydrogen environment.

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