Environmentally Assisted Cracking Research Articles

Characterization of Mechanical Heterogeneity and Study of the Mechanical Field at the Tip of the Stationary-Growing Crack in Dissimilar Metal Welded Joints

Abstract The mechanical heterogeneity in local areas of dissimilar metal welded joints and the micro-area mechanical state at the crack tip are key factors in determining Environment-Assisted Cracking (EAC). Traditional methods for acquiring material mechanical properties often result in destructive damage to specimens, while conventional “sandwich” models exhibit abrupt changes in interfacial mechanical properties and a lack of research into the mechanical field at the tip of the stationary or growing crack. In light of these challenges, this study, based on the analysis of microstructures in localized regions of the welded joint and the acquisition of material mechanical properties through indentation tests, developed a user-defined material subroutine (UMAT) to characterize the mechanical properties of non-uniform local areas within the welded joint. Additionally, it investigated the mechanical field at the tip of the stationary—growing crack using an integral method and a de-bond technique. The results indicate that non-destructive indentation tests can accurately acquire the material mechanical properties of local areas in the welded joint. Notably, significant changes in mechanical properties typically occur in the material interface regions, making them vulnerable points for potential failure. Furthermore, under the same load, mechanical heterogeneity significantly influences the distribution of the mechanical field at the crack tip. Crack propagation induces alterations in crack tip stresses, resulting in noticeable residual stresses and strains along the propagation path.

Environmentally-assisted cracking of electropolished 316L stainless steel in molten FLiNaK salt

Environmentally-assisted cracking is a well-known and extensively studied phenomenon in light water reactor environments but remains relatively unexplored in proposed molten salt reactor systems where the mechanisms at play are expected to be quite different. Here, slow strain rate testing has been performed on 316L stainless steel tensile specimens during simultaneous exposure to a molten LiF-KF-NaF eutectic salt environment at 600°C with a strain rate between 1E-5 to 1E-7 s-1. Sample ductility and ultimate tensile strength were both observed to decrease for slower strain rates/longer salt exposures. Post-mortem characterization of fractured specimens revealed Fe deposits and Cr- and O-rich precipitates decorating surface grain boundaries and crack surfaces, suggesting a cracking mechanism driven by embrittlement of the crack tip due to oxide formation. Unlike previous studies, intergranular Cr corrosion into the bulk was not observed, and distinct differences in surface morphology between electropolished and non-electropolished sample surfaces are reported. Trace metal salt chemistry measurements showed accumulation of 316L alloying elements over the course of the tests. It appears likely that the surface oxide layer induced by electropolishing, in addition to oxygen and moisture impurities in the salt, led to the formation of LiCrO2 which had a net passivating effect that prevented significant bulk corrosion, though some interplay between mechanical and environmental stressors is still observed.

Surface stress can initiate environment-assisted fracture in metals.

Controlling environmental effects in surface plasticity/fracture of metals is of interest for areas as diverse as manufacturing processes, product performance, and structural safety. The key to controlling these effects is understanding the effect of adsorbates on surface energy (γ) and surface stress (f). While γ has been well studied, the role of surface stress has received much less attention. We characterize surface stress induced in metals by adsorption of organic monolayers. Linear alkanoic acids of varying chain length (3-18) are deposited by molecular self-assembly onto one side of an aluminum cantilever, several centimeters in length. The surface stress is estimated from in situ measurement of the cantilever deflection. We find that the organic adsorbates induce large surface stress of -4 to +30N/m. Furthermore, we show that f may be tuned by varying adsorbate-molecule chain length. The stress data explain beneficial embrittlement of metal surfaces by organic adsorbates in cutting and comminution processes, and point to a critical role, hitherto ignored, for f in environment assisted cracking (EAC) phenomena. Our results suggest opportunities for utilizing controlled environment-assisted fracture as an aid-fracture as a friend-to enhance material removal processes, apart from using surface stress itself as an experimental probe to explore various manifestations of EAC.

A materials selection framework for fastener-in-panel geometries using FEM and LEFM, to mitigate coating degradation and environmentally assisted cracking

A finite element method (FEM) model was used to determine the potential, current, and current density distributions for a multi-material fastener/hole-in-plate configuration in an atmospheric environment. The plate consisted of bare Pyrowear 675 with or without a ZnNi coating, and the fastener consisted of Ti-6Al-4V with or without an anodization surface treatment. The potential distribution within the fastener hole was the focus of this work, as this region would represent the location of highest stress within the fastener/panel geometry. Separately, existing literature data were augmented by fracture mechanics-based evaluations of the environment-assisted cracking behavior of Pyrowear 675 as a function of electrode potential Pyrowear 675 in 3.0 M NaCl. Combining the fracture mechanics and FEM results allowed for a unified framework which was able to narrow a material selection matrix of 13 total scenarios to three scenarios, in an atmospheric environment of 0.6 M NaCl, specifically. The delayed drying out of occluded regions after the surface electrolyte has been evaporated was accounted for, with only one of the studied material selection combinations able to reduce the crack susceptibility under those conditions. A single pit within the fastener hole was also considered, and it was determined that the size of the pit had a larger impact on the potential than the location of the pit, which will aid in future computational assumptions.

The influence of heat treatment on microstructure and mechanical response of a newly developed non-equimolar AlCrCuFeNi high-entropy alloy: Experiments and numerical modeling

High Entropy Alloys (HEA), or more generally, Complex Concentrated Alloys (CCA) have recently shifted the manufacturing and design paradigms of metallic alloys which are more resistant and strong to mechanical loadings as well as environmental-assisted cracking. Although an extensive body of results on these special alloying systems has accrued over recent years, there are still many unknowns related to composition and microstructure and their influences on plastic deformation and failure. In this exploratory study, a new non-equimolar Multi-Principal Element Alloy along with a few annealed variant configurations is investigated by means of microstructure characterization techniques along with computational modeling. The latter is implemented to unveil the interaction of distinct mechanisms controlling the deformation process and failure in this system. For macroscopic behavior, a phenomenological approach is used to understand the plasticity and fracture under different stress states, while a mesoscale-level crystal plasticity model is carried out to determine slip system activity and its influence on plastic deformation. Overall, the new alloy exhibits rising strain hardening curves regardless of the annealing time period, but the onset of fracture is highly sensitive to heat treatment time.

Effect of Chloride Concentration on the Environment-Assisted Cracking Behavior of an Al-Mg Alloy in Atmospheric Environments

The effect of chloride concentration on the environment-assisted cracking (EAC) behavior of AA5083-H131 in atmospheric environments was investigated using high-fidelity fracture mechanics-based testing and concurrent electrochemical potential measurements. EAC susceptibility was found to increase across all environments as chloride concentration increased, denoted by a decrease in the threshold stress intensity and faster stage II crack growth rates. However, EAC susceptibility for a given chloride concentration decreased across all chloride concentrations as cathodic limitation due to solution geometry effects increased. These results are analyzed in the context of the proposed anodic dissolution-enabled hydrogen embrittlement mechanism for EAC in Al-Mg alloys. Specifically, the increase in EAC susceptibility noted at higher chloride concentrations is postulated to arise from an increased overpotential for hydrogen production at the crack tip. Conversely, the decrease in EAC susceptibility observed as the solution geometry becomes more restrictive is attributed to cathodic limitation at the bulk surface decreasing dissolution at the crack tip, resulting in a concomitant less aggressive crack chemistry, and thus lower levels of hydrogen production and uptake at the crack tip. A close correlation between the open-circuit potential on the bulk specimen surface and the crack growth kinetics was also observed across all environments and chloride concentrations, with higher chloride concentrations and cathodic limitations resulting in larger changes in electrochemical potential. This correlates well with known electrochemical potential-dependent EAC observations for these alloys.

Experimental Evaluation of KIEAC of a Carbon Steel Using the Pin-Loaded SENT Geometry

Abstract The experimental determination of the threshold stress intensity factor for environment-assisted cracking (KIEAC) is described by several standards, which allow the use of different specimen geometries and methodologies for crack length estimation. In some cases, the combination of structure, specimen size, or both, main loading direction, and crack orientations of the component that need to be characterized limit the use of standardized geometries. Consequently, alternative geometries must be used. In this study, fatigue pre-cracked pin-loaded single edge notched tension specimens as defined by BS 8571:2018, Method of Test for Determination of Fracture Toughness in Metallic Materials Using Single Edge Notched Tension (SENT) Specimens, were applied for the experimental evaluation of the KIEAC of a carbon steel. The specimens were tested in deaerated substitute ocean water solution saturated with carbon dioxide at 40°C and at 1 and 10 bar (100 and 1,000 kPa) under constant load conditions with incremental (step) loading. The crack length during the tests was monitored by direct current potential drop, which was helpful for defining the applied K corresponding to the onset of subcritical crack growth (KIEAC). Additionally, fractographic analysis of KEAC specimens and results from the fracture toughness evaluation of this material in air at room temperature have also been reported.

The Effect of Crack-Initiating Feature on the Environment-Assisted Cracking Behavior of Sensitized AA5456-H116 in Marine Environments

The influence of crack-initiating feature on the environment-assisted cracking (EAC) behavior of sensitized AA5456-H116 exposed to marine environments is assessed via fracture mechanics-based testing. Specimens that contained either a traditional fatigue precrack or purposefully introduced intergranular corrosion fissures were immersed in 0.6 M NaCl and polarized to select electrochemical potentials while held at a constant force. The measured crack length vs. time relationships from these experiments reveal that the two specimen geometries yield similar crack growth rates at −900 mVSCE and after the onset of accelerated crack propagation at −800 mVSCE. However, precorroded specimens exhibit significantly shorter times to failure than the precracked specimens at −800 mVSCE due to increased crack growth rates at the start of the experiment. The mechanical, environmental, and material factors that could contribute to the initially increased EAC susceptibility of the precorroded specimens are identified using a generalized model for EAC. Analysis of these possible causal factors suggests that the increased susceptibility is due to a residual, initially more deleterious crack chemistry at the occluded corrosion fissure tip from the aggressive galvanostatic polarizations used to accelerate fissure growth. The implications of these results on the efficacy of traditional fracture mechanics-based methods for quantifying EAC susceptibility are discussed.

Effects of sensitization on environmentally assisted cracking of AA5083-H128 Al–Mg alloy

The influence of sensitization on the precipitation behaviour and environmentally assisted cracking (EAC) of AA5083 alloy with the –H128 temper have been investigated. 80 °C/500 h and 80 °C/1000 h sensitized specimens exhibit discontinuous Mg-rich precipitates along the grain boundaries, whereas almost continuous β′ phase is present along the grain boundaries in the 175 °C/100 h sensitized material. EAC susceptibility increases with increasing exposure time and elevated temperature. The relationship between nitric acid mass loss test (NAMLT) values and mechanical test results indicates that specimens with a NAMLT value greater than 25 mg/cm2 exhibit severe EAC. The test environment affects the degree of EAC due to the combined effects of anodic dissolution at the crack tip, hydrogen evolution, and hydrogen embrittlement. AA5083-H128 exhibits lower EAC susceptibility than AA5083-H131, likely due to its lower yield strength. High yield strength can produce more Mg-rich precipitates after sensitization, increase the constraint of the crack tip material and accelerate the diffusion rate of H atoms in the process zone of the crack tip.

Effect of surface machining on the environmentally-assisted cracking of Alloy 182 and 316L stainless steel in light water reactor environments: results of the collaborative project MEACTOS

Abstract The main objective of the EU-funded project mitigating environmentally-assisted cracking through optimisation of surface condition (MEACTOS) was to gain knowledge on the ability of different surface machining procedures to mitigate environmentally-assisted cracking (EAC) in typical light water reactor structural materials and environments. Surfaces of cold-worked (CW) type 316L austenitic stainless steel and nickel-based weld metal Alloy 182 flat tapered tensile specimens were machined using different processes. EAC initiation susceptibility of these specimens was evaluated using constant extension rate tensile (CERT) tests under simulated boiling water reactor (BWR) and pressurized water reactor (PWR) conditions and assessed using constant load experiments. More than a hundred tests were performed covering about 10 years of autoclave testing time. Only minor or no measurable improvements in EAC initiation susceptibility as a function of surface treatments (grinding or advanced machining) compared to the standard industrial face milling were demonstrated. In most cases, the stress thresholds for EAC initiation determined in constant load tests confirmed the trend obtained from CERT tests. This paper summarises the most important results and conclusions concerning the EAC initiation behaviour for the CW 316L and Alloy 182 under reducing PWR and oxidizing BWR conditions.

Computational study of the geometrical influence of grain topography on short crack propagation in AA7XXX series alloys

Intergranular Environmentally-Assisted Cracking (EAC) has recently been reported to be an issue of concern in new-generation 7000 series aluminium alloys, such as AA7085, when exposed to humid air. The cracking process occurs in a highly brittle manner almost exclusively along grain boundaries (GB's) and has been attributed to hydrogen embrittlement, probably by GB decohesion within the stress field at the crack tip. Currently, how the highly heterogeneous grain structures found in these partially recrystallized materials impact the growth behaviour of microstructurally short cracks is poorly understood. In particular, there is expected to be a high sensitivity to the grain structure in the transition from initiation to sustained propagation, where the local mechanical driving force is very sensitive to the crack path. Volume Elements, VE's, with synthetic grain structures have been generated from real microstructure and texture data, so that the effects of important grain structure variables can be explored in crystal-plasticity simulations, to understand the extent to which typical grain-structural features affect the driving force for short-crack growth. Specifically, by considering the effect of different uncrystallised grain aspect ratios and embedding recrystallised grains in the model, the strain energy release rate has been calculated as a function of crack path. This has revealed large reductions and fluctuations in the driving force for short cracks in relation to the local grain structure encountered by the crack tip, which have been estimated by the model.

Kinetics of corrosion reactions on press hardened steel in atmospheric conditions under thin electrolyte films

Steels with high mechanical performance are prone to hydrogen embrittlement and environmental assisted cracking. Under atmospheric corrosion conditions, the source of hydrogen can be the steel corrosion process itself or galvanic coupling with a metallic coating. Electrochemical behaviour of Press Hardened Steel (PHS) under electrolyte films of different thicknesses using local electrochemical techniques was studied on a fundamental level. Scanning Vibrated Electrode Technique (SVET) was applied to study the evolution and localization of the corrosion process during PHS immersion in NaCl electrolyte. Kelvin Probe (KP) was used as a reference electrode to obtain cathodic and anodic polarization curves on PHS surfaces which were covered by thin electrolyte films (60 to 500 µm) of 0.1 M NaOH and 0.6 M NaCl. For both electrolytes, a strong increase in the oxygen reduction rate due to the decreasing of electrolyte thickness has been clearly demonstrated. Data are correlated well with a theoretical plot determined by Nernst-Fick equation. The influence of the rust layers on the kinetics of corrosion reactions under thin electrolyte films was investigated using KP.

Environment-assisted cracking of AZ31 magnesium alloy in a borate buffer solution containing ammonium thiocyanate under various potentials

The environment-assisted cracking behavior of AZ31 magnesium alloy was investigated using tensile tests at cathodic and corrosion potentials in a Na2B4O7∙10H2O solution containing NH4SCN and in air. Although the mechanical properties of the AZ31 with an initial strain rate of 10−4 s−1 were independent of the environments, those degraded in the solution with an initial strain rate of 10−6 s−1. The total elongation became smaller at higher potentials. The average hydrogen absorption rate increased with a positive potential shift. These facts imply that environment-assisted cracking became more severe under relatively high potential owing to corrosion accompanied by enhanced hydrogen absorption.

Stress corrosion cracking in fuel-grade ethanol: The role of the testing methodology

The increase in fuel-grade ethanol (FGE) consumption demands efficient and safe storage and transportation. However, depending on the raw material used for ethanol production, stress corrosion cracking (SCC) might be a major concern. This work evaluated the API 5L X70 steel susceptibility to SCC in simulated fuel-grade ethanol (SFGE), corn, and sugar cane FGE. The maximum stress intensity factor (Kmax.) was determined from KR curves, and the stress intensity factor threshold for environment-assisted cracking (KEAC) was obtained from the direct current electric potential difference (DCEPD) versus load-line displacement (LLD) curves. The results showed that Kmax. was weakly affected by the environment (different variants of ethanol), although brittle fracture comprising cleavage-like features, intergranular facets, and secondary cracks was observed for SFGE and corn FGE. Under the specific set of testing conditions adopted here, the parameter KEAC was effective in showing that the API 5L X70 steel is quite sensitive to SCC in SFGE and corn FGE, and not susceptible to this progressive cracking process in sugar cane FGE.

Coupling Fracture Mechanics Experiments and Electrochemical Modeling to Mitigate Environment-Assisted Cracking in Engineering Components

Environment-assisted cracking (EAC) is a pertinent failure mode for many applications and industries, but the design of robust EAC mitigation strategies can be challenging due to the number of material and environmental factors that affect EAC behavior. In this study, a coupled experimental-modeling approach for designing EAC mitigation strategies in a standard panel-and-fastener geometry is presented. Fracture mechanics-based testing is executed on a high-performance steel (Pyrowear 675) immersed in 0.6 M NaCl to assess the effect of electrode potential and loading rate on EAC susceptibility. Finite element modeling (FEM) is then used to calculate the electrode potential distribution across the panel for four realistic EAC mitigation strategies (anodized fastener, fully coated panel, selectively coated panel, and bare panel/fastener). The FEM and EAC susceptibility data are synthesized to inform the efficacy of each proposed mitigation strategy. Results demonstrate that the anodized fastener and fully coated panel approaches are likely to promote EAC, while the selectively coated panel and all-bare strategies mitigate EAC. The benefits and limitations of this coupled approach for mitigating EAC are then discussed.

Effect of thermal aging on the environmental assisted cracking behavior of 308L weld metal in high temperature water

The effect of thermal aging on environmental assisted cracking (EAC) of 308 L weld metal was investigated. Experimental results reveal that thermal aging promotes corrosion fatigue (CF) crack growth with extensive inter-dendritic cracking, but has a limited effect on the stress corrosion cracking (SCC) growth under constant loads. The higher crack tip strain rate and the enhanced preferential oxidation of deteriorated δ-ferrite are responsible for the enhanced CF susceptibility after thermal aging. The dispersed δ-ferrites and the decreased crack tip strain rate account for the high SCC resistance under constant load regardless of the thermal aging.

A sampling of environmental data, and its presentation, from a multi-role U.S. coast guard aircraft

Abstract This work presents a summary of environmental data from 3600 h of data collected during operations of a U.S. Coast Guard HC-130H aircraft performing its routine missions over a five-year period. The aircraft operated from multiple U.S. and deployed locations during the data collection period in the tropical and mid-latitudes at altitudes up to 8.5 km (28 kft). The aircraft collected pressure, temperature and humidity data during the period. No aerosol components were sampled (chlorides, sulfur dioxide, etc.). While there was no Time of Wetness sensor, the ISO 9223 definition is used for the present work as an estimator. These data are presented in the context of research into corrosion and environmental severity, or the potential conditions for it. About 40% of the data were collected while the aircraft was parked on the ground at various based and deployed locations. The purpose of this work is to present and summarize the flight data as an aid in providing some context for future research into environmental effects as they relate to both corrosion and environmentally assisted cracking (EAC) of aircraft structure, and perhaps for comparisons with existing or future datasets from aircraft having other missions. Prediction models need realistic, real-world inputs, such as those presented here. An example for the use of these data in corrosion prediction based on the ISO 9223 international standard is presented. Perhaps not surprisingly, these data show that, for this aircraft, conditions most favorable to corrosion occurred while the aircraft was on the ground.

Notch sensitivity and short cracks tolerance in a super 13Cr stainless steel under sulfide stress corrosion cracking conditions

Abstract Notch sensitivity under sulfide stress corrosion cracking (SSC) conditions is quantified in this work, considering its tolerance to short cracks that start at notch tips and become non-propagating after growing for a short while. The considered material is an UNS S41426 super 13Cr5Ni2Mo martensitic stainless steel, frequently used in pipelines to transport aggressive fluids in offshore applications. Tolerance to short SCC cracks depends on the notch size and shape, on the stress gradient ahead of its tip, and on basic material resistances to crack initiation S SSC and growth K ISSC inside the aggressive environment. The proposed notch-sensitivity model can be a powerful and economical alternative design tool to substitute traditional pass/non-pass criteria normally used to choose materials for SSC and similar environmentally assisted cracking (EAC) service conditions. This model is validated by testing the steel into an aqueous solution of 100 g/L of Cl−, pH 4.0, 25 kPa of H2S, and 75 kPa of CO2, at 23 ± 2 °C. After measuring S SSC (461 ± 23 MPa) and K ISSC (36.9 ± 0.6 MPa√m), short crack tolerance predictions are verified on notched specimens loaded under a peak stress at their tips σ max = 0.95⋅S Y >> S SSC, where S Y = 826 MPa is the yield strength of the tested steel.

Environment-Assisted Crack Initiation in Aluminum Alloys Studied by Local Probe Techniques

Environment-assisted crack initiation in aluminum alloys is strongly related to the physical and chemical reactivity of intermetallic particles (IMPs) whatever their location, i.e., at grain boundaries or in the matrix. Therefore, this paper first focuses on the most recent contribution of microscale local probe techniques to the study of processes occurring at the coarse IMPs that need to be taken into account in the initiation stage of environment-assisted cracking (EAC). A critical review of microscale electrochemistry, chemistry, and analysis of the influence of stress on IMPs leading to the microscale analysis of crack incubation is presented. Moreover, the contribution of hydrogen to the initiation of EAC remains a widely debated issue. Therefore, the second part of this paper more specifically reviews and summarizes the contribution of some specific local probe techniques to a better understanding of the contribution of hydrogen enrichment to environment-assisted crack initiation. The remaining challenges in future studies needed to fully elucidate hydrogen-assisted cracking mechanisms at the microscale are discussed.

Susceptibility to Pitting and Environmentally Assisted Cracking of 17-4PH Martensitic Stainless Steel Produced by Laser Beam Melting.

Materials produced by additive manufacturing (AM) often have different microstructures from those obtained using conventional metallurgy (CM), which can have significant impacts on the materials’ durability, and in particular, resistance to corrosion. In this study, we were concerned with the susceptibility to pitting and environmentally assisted cracking (EAC) of 17-4PH martensitic stainless steel (MSS). We focused on the evolution from pitting to EAC, and the behaviour of MSS produced by AM was compared with that of its CM counterpart. Potentiodynamic polarisation tests were combined with chronoamperometry measurements performed without and with mechanical loading to study both stable and metastable pitting and the influence of stress on these processes. EAC tests were carried out and combined with observations of fracture surfaces. MSS produced by AM was more resistant to pit initiation due to fewer and finer NbC particles. However, the propagation kinetics of stable pits were higher for this MSS due to a higher amount of reversed austenite. The stress was found to stabilise the metastable pits and to accelerate the propagation of stable pits, which resulted in an increased susceptibility to EAC of the MSS produced by AM. These results clearly highlighted the fact that the reversed austenite amount has to be perfectly controlled in AM processes.