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.
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.
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.
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.
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.
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 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.
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.
