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Fatigue crack growth rates of X100 steel welds in high pressure hydrogen gas considering residual stress effects

Engineering Fracture Mechanics

Ronevich, Joseph; D'Elia, Chris; Elia, Michael R.'.

Fatigue crack growth rate (FCGR) data were measured in high pressure hydrogen gas versus stress intensity factor range (ΔK) in specimens removed from a X100 welded steel pipe. Three distinct regions of the pipe weld were examined: base metal, weld fusion zone, and heat affected zone. Tests were performed at a load ratio (R) of 0.5, frequency of 1 Hz, and at a hydrogen gas pressure of 21 MPa. Tests were also performed in air at 10 Hz as a reference. Fatigue crack growth rates were observed to be over an order of magnitude higher for tests performed in hydrogen compared to the rates from tests in air. Residual stress measurements were collected on identical specimens cut from the base metal, weld, and heat affected zone to account for their influence on measured FCGR data. The slitting method provided residual stress and residual stress intensity factor (Kres), the effect of which was removed from the FCGR data using Knorm in order to provide a more direct comparison of crack growth resistance of the base metal, weld and heat affected zone. Prior to accounting for residual stress, FCGR in hydrogen gas appeared to be highest in the weld fusion zone. Furthermore, after accounting for residual stress effects, the weld fusion zone FCGR data converged to the base metal FCGR data, which underscores the importance of accounting for residual stress effects when assessing fatigue performance.

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Orientation dependence of hydrogen accelerated fatigue crack growth rates in pipeline steels

American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP

Song, Eun J.; Ronevich, Joseph

One of the most efficient methods for supplying gaseous hydrogen long distances is by using steel pipelines. However, steel pipelines exhibit accelerated fatigue crack growth rates in gaseous hydrogen relative to air. Despite conventional expectations that higher strength steels would be more susceptible to hydrogen embrittlement, recent testing on a variety of pipeline steel grades has shown a notable independence between strength and hydrogen assisted fatigue crack growth rate. It is thought that microstructure may play a more defining role than strength in determining the hydrogen susceptibility. Among the many factors that could affect hydrogen accelerated fatigue crack growth rates, this study was conducted with an emphasis on orientation dependence. The orientation dependence of toughness in hot rolled steels is a well-researched area; however, few studies have been conducted to reveal the relationship between fatigue crack growth rate in hydrogen and orientation. In this work, fatigue crack growth rates were measured in hydrogen for high strength steel pipeline with different orientations. A significant reduction in fatigue crack growth rates were measured when cracks propagated perpendicular to the rolling direction. A detailed microstructural investigation was performed, in an effort to understand the orientation dependence of fatigue crack growth rate performance of pipeline steels in hydrogen environments.

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Validating Hydrogen Concentrations Ahead of Crack Tips

Ronevich, Joseph; Fonseca, Paulo

Current models for hydrogen embrittlement rely on adjustable parameters to correct for uncertainties in crack tip stress fields and subsequent H2-concentrations. Techniques are needed to quantify these concentrations ahead of crack tips in mechanically loaded materials, providing data for model calibration and validation. The goal of this work was to establish advanced analytical techniques to detect and quantitatively measure hydrogen ahead of cracks in stressed solids. Two advanced analytical techniques, kelvin probe force microscopy (KPFM) and nuclear reaction analysis (NRA), were explored to evaluate the feasibility to provide qualitative and quantitative H2-concentration fields in geometries designed to be 'loaded' while under observation. The feasibility of the KPFM technique at detecting hydrogen was evaluated using electrochemically precharged hydrogen as well as a mixed hydrogen gas atmosphere. The KPFM technique was able to detect the presence of elevated stress and hydrogen concentrations ahead of a tensile loaded crack tip. The results suggest that KPFM is a viable technique for qualitatively imaging changes in stress and hydrogen concentrations on the scale needed to inform predictive models. KPFM could be used to provide local stress and hydrogen variations associated with hydrogen traps or different phases which require sensitive measurements on the micron scale. NRA provided quantitative measurements of the hydrogen-isotope deuterium ahead of a tensile loaded notch, however, the vacancy formation due to the incident high energy He 3 beam overwhelmed stress-assisted enhancement of deuterium concentrations such that the effect of stress was overshadowed in this analysis. Modeling of the chemo- mechanical hydrogen concentration change was used to verify this observation.

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Results 151–175 of 205
Results 151–175 of 205
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