Hydrogen-enhanced Fatigue Crack Growth Research Articles

Hydrogen-enhanced fatigue crack growth of martensitic stainless steel: A predictive model and experimental validation

Atomic hydrogen (H) diffusion in metallic structures affects the mechanical properties of steel alloys. However, the effect of hydrogen embrittlement on the fatigue crack propagation rate (FCGR) is not fully understood, and serious uncertainties can affect the design and inspection schedules of hydraulic turbine runners based on the defect-tolerance approach. The FCGR in a complex microstructure such as tempered martensitic stainless steel is governed by the H content, stress distribution, and microstructure at the crack tip. The synergetic interactions between these parameters should be kinetically studied as the crack propagates. In this study, an original model was proposed to predict the influence of H on the fatigue crack propagation rate. The model was developed specifically for tempered martensitic stainless steels containing austenite. Subsequently, it was validated through experiments performed on 415 martensitic stainless steel containing 20% of reformed austenite (RA). The material’s FCGR was tested in its raw condition, also after charging with H. Compact tension (CT) specimens were tested at two constant stress intensity factor ranges (ΔK = 8 MPa.m0.5 and 15 MPa.m0.5) and three cyclic loading frequencies (f = 35 Hz, 3.5 Hz, and 0.35 Hz). The results show a very good agreement with the predictions of the model. Moreover, both the model and the experimental results reveal that there is a critical ΔK that is dependent on the loading frequency at which the impact of H on the FCGR is maximum. Moreover, as predicted by the model, a decrease in the loading frequency led to an increase in the susceptibility of the FCGR to H.

Hydrogen enhanced fatigue crack growth rates in a ferritic Fe-3 wt%Si alloy and a X70 pipeline steel

It is well known that ferrous materials can be damaged by absorption of hydrogen. If a sufficient quantity of hydrogen penetrates into the material, static fracture and the material's fatigue performances can be affected negatively, in particular causing an increase in the material crack growth rates. The latter is often referred as Hydrogen Affected-Fatigue Crack Growth Rate (HA-FCGR). It is therefore of paramount importance to quantify the impact, in terms of hydrogen induce fatigue crack growth acceleration in order to determine the life of components exposed to hydrogen and avoid unexpected catastrophic failures. In this study, in-situ fatigue crack growth rate testing on Compact Tension (CT) specimens were carried out to determine the fatigue crack growth behaviour for a Fe-3 wt%Si alloy and X70 pipeline steel. Tests were carried out in two environmental conditions, i.e. laboratory air and in-situ electrochemically charged hydrogen, and different mechanical conditions in terms of load ratio (R = 0.1 and R = 0.5, for the Fe-3 wt%Si, R = 0.1 for the X70 steel) and test frequency (f = 0.1 Hz, 1 Hz and 10 Hz) were adopted under electrochemically charged hydrogen conditions. The results show a clear detrimental effect of H for the specimens tested in hydrogen when compared to the specimens tested in air for both materials and that the impact of hydrogen is test frequency-dependent: the hydrogen induced acceleration is more prominent as the frequency is decreased. Post-mortem surface investigations consistently relate the global crack growth acceleration to a shift from transgranular to Quasi-cleavage fracture mechanism. Despite such consistency, the acceleration factor strongly depends on the material: Fe-3wt%Si features acceleration up to 1000 times while X70 accelerates up to 76 times when compare to the material fatigue crack growth rate recorded in air. Observation of the deformation activities in the crack wake in relation to the transition into hydrogen accelerated regime in fatigue crack growth show a tendency toward restricted plastic activity in presence of hydrogen.

Hydrogen-enhanced fatigue crack growth in a single-edge notched tensile specimen under in-situ hydrogen charging inside an environmental scanning electron microscope

Fatigue crack growth (FCG) test was done on a pre-cracked single-edge notched tensile (SENT) specimen with oligocrystalline ferritic structure. Innovative in-situ hydrogen (H)- charging by plasma inside an environmental scanning electron microscope (ESEM) was adopted to directly observe the H influence on the FCG behavior of this material. Diverse in-situ and post-mortem characterization methods including secondary electron imaging, backscatter electron imaging, electron backscatter diffraction (EBSD) and scanning probe microscopy (SPM) were used to investigate the material's behavior. It was observed that the crack growth rate was enhanced by about one magnitude when H was charged, in comparison with the reference test in vacuum (Vac). The FCG procedure was concluded as strongly associated with the plasticity evolution in the vicinity of the crack-tip. A simple model based on the restricted plasticity was proposed for the H-enhanced FCG behavior. A peculiar frequency dependency of the H-enhanced FCG behavior was observed at low loading frequencies (0.015 Hz–0.15 Hz): under the same in-situ H-charging condition, a lower frequency gave a slower crack growth rate and vice versa. This behavior was explained by the thermally activated dislocation motion correlated with the plasticity shielding effect during crack growth.

Hydrogen-enhanced fatigue crack growth behaviors in a ferritic Fe-3wt%Si steel studied by fractography and dislocation structure analysis

The effect of hydrogen (H) on the fatigue behavior is of significant importance for metallic structures. In this study, the hydrogen-enhanced fatigue crack growth rate (FCGR) tests on in-situ electrochemically H-charged ferritic Fe-3wt%Si steel with coarse grain size were conducted. Results showed strong difference between the H-charged and the non-charged conditions (reference test in laboratory air) and were in good agreement with the results from literature. With H-charging, the fracture morphology changed from transgranular (TG) type to “quasi-cleavage” (“QC”), with a different fraction depending on the loading frequency. With the help of electron channeling contrast imaging (ECCI) inside a scanning electron microscope (SEM), a relatively large area in the failed bulk specimen could be easily observed with high-resolution down to dislocation level. In this work, the dislocation sub-structure immediately under the fracture surfaces were investigated by ECCI to depict the difference in the plasticity evolution during fatigue crack growth (FCG). Based on the analysis, the H-enhanced FCG mechanisms were discussed.

Peculiar temperature dependence of hydrogen-enhanced fatigue crack growth of low-carbon steel in gaseous hydrogen

The peculiar temperature dependence of hydrogen-enhanced fatigue crack growth (HEFCG) of low-carbon steel in hydrogen gas was successfully interpreted in terms of ‘trap-site occupancy’ of hydrogen. HEFCG decreased with increasing temperature in hydrogen gas at 0.7 MPa and 298 to 423 K due to lower occupancy of trap sites at higher temperatures. In hydrogen gas at 90 MPa, HEFCG was insensitive to the temperature because most of the trap sites were occupied by hydrogen, regardless of the temperature. Trap sites with a binding energy of 47 kJ/mol, corresponding approximately to the dislocation core, dominated the temperature dependence of HEFCG.

Hydrogen Enhanced Fatigue Crack Growth Rates in a Ferritic Fe-3wt%Si Alloy

It is well known that the presence of hydrogen in ferrous materials promotes both static fracture and affect the material fatigue crack growth rates. The latter is often referred to as Hydrogen Enhanced Fatigue Crack Growth Rate (HE-FCGR) which defines the reduction of crack growth resistance of the material under cyclic stresses when hydrogen is present. When it comes to the determination of the life of components exposed to hydrogen it is therefore of paramount importance to establish such hydrogen induced variation in crack speed in the material in order to avoid unexpected catastrophic failures. In this study the fatigue crack growth rate was determined for a Fe-3wt%Si alloy. Compact tension specimens were used to determine the Paris regime of the fatigue crack growth rate curve of the material. Two environmental conditions were investigated: laboratory air and in-situ electrochemically charged hydrogen. Different mechanical conditions, in terms of load ratio (R=0.1 and R=0.5) and test frequency (f=0.1 Hz, 1 Hz and 10 Hz), were used under electrochemically charged hydrogen conditions. The results show that compared to the specimens tested in air, there is a clear detrimental effect of H for the specimens tested in hydrogen, in terms of accelerated crack growth. The strength of the impact of hydrogen in enhancing the fatigue crack growth rates of the Fe-3wt%Si alloy clearly depends on the test conditions. Fractographic investigations were also used to unveil the mechanisms involved in the process leading to accelerate crack growth in presence of hydrogen.

Influence of gaseous hydrogen on plastic strain in vicinity of fatigue crack tip in Armco pure iron

A multi-scale characterisation of the crack tip plasticity has been investigated in a fatigue crack propagation under gaseous hydrogen at gas pressure of 35 MPa in a commercially pure iron, Armco iron. The dislocation structure beneath a fracture surface was observed by a Transmission Electron Microscopy(TEM), and the cyclic and monotonic plastic zones were evaluated by an Out-of-Plane Displacement (OPD) measurement. By the TEM observation in a non-accelerated regime (ΔK = 11 MPa×m1/2), a dislocation cell structure was observed even in the brittle intergranular fracture in hydrogen. This result indicates a certain amount of plastic strain is introduced into the grains in front of an intergranular crack in hydrogen, and this may explain the mechanism of hydrogen-induced intergranular fatigue crack propagation. On the other hand, in an accelerated regime (ΔK = 18 and 20 MPa×m1/2), a distribution of scattered dislocation tangles without any cell or vein structure was observed in hydrogen. Besides, the inhibition of the cyclic plasticity near the crack path in hydrogen was confirmed by the OPD measurement. These results are clear evidences of hydrogen-induced localization of cyclic plasticity in the vicinity of a crack tip, which suggests a mechanism model of hydrogen-enhanced fatigue crack growth based on the plasticity localization.

Hydrogen-enhanced fatigue crack growth in steels and its frequency dependence.

In the context of the fatigue life design of components, particularly those destined for use in hydrogen refuelling stations and fuel cell vehicles, it is important to understand the hydrogen-induced, fatigue crack growth (FCG) acceleration in steels. As such, the mechanisms for acceleration and its influencing factors are reviewed and discussed in this paper, with a special focus on the peculiar frequency dependence of the hydrogen-induced FCG acceleration. Further, this frequency dependence is debated by introducing some potentially responsible elements, along with new experimental data obtained by the authors.This article is part of the themed issue 'The challenges of hydrogen and metals'.

Illuminating the chemo-mechanics of hydrogen enhanced fatigue crack growth in aluminum alloys

The presence of elemental hydrogen is known to accelerate fatigue crack growth in aluminum alloys. However, a direct link between experimental data and the governing atomistic mechanisms has remained elusive. Here we present a series of computational studies, across multiple length scales, directly linking an atomistic mechanism to experimental data for a specific aluminum alloy. Starting with an ab initio investigation of hydrogen bonding near the (1 1 1) aluminum surface, we quantify the effects of hydrogen surface impurities on slip and decohesion. We then modify an aluminum-only interatomic potential to reproduce ab initio trends by strategically shielding critical surface bonds in accordance with the environmental exposure level. The strategic shielding approach is used within a coupled atomistic-continuum discrete dislocation framework to predict the effect of hydrogen on near threshold fatigue crack growth rates. The predicted trends agree with published experimental data, suggesting that hydrogen enhanced surface deformation is a key failure mechanism for aluminum alloys in humid environments. (C) 2015 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Hydrogen enhanced fatigue crack growth in an HSLA steel

Fatigue crack growth rate (FCGR) for an HSLA steel was studied with in-situ hydrogen charging. The effects of different parameters, like stress intensity range (ΔK), frequency, load ratio (R), stress values and crack length have been investigated. The hydrogen contribution to FCGR decreased with increasing ΔK. FCGR was inversely dependent on frequency. The role of loading strain rate on the hydrogen enhanced FCGR was explained. The effect of load ratio on hydrogen enhanced FCGR was not monotonic. A dependence of FCGR of hydrogenated samples on crack length was observed and explained.

PS22 球状黒鉛鋳鉄における水素助長疲労き裂進展に及ぼす繰返し速度の影響

PS22 球状黒鉛鋳鉄における水素助長疲労き裂進展に及ぼす繰返し速度の影響

A new mechanism in hydrogen-enhanced fatigue crack growth behavior of a 1900-MPa-class high-strength steel

This paper presents a new mechanism controlling the acceleration of fatigue crack growth of a hydrogen-charged high-strength steel (bearing steel SAE52100, σ ult > 1, 900MPa, HV = 569). Three- dimensionally complicated shape of a primary crack and secondary cracks were observed in hydrogen- charged specimens. Marked acceleration of fatigue crack growth in the presence of hydrogen was observed particularly at low test frequency, and was attributed to the initiation and successive coalescence of secondary cracks formed ahead of primary crack. These secondary cracks were produced along prior-austenite grain boundaries and carbide boundaries, or by direct cracking of carbides. Surprisingly, secondary cracks were observed outside the ordinary plastic zone ahead of the crack tip. TEM observation elucidated that the secondary cracks outside the crack tip plastic zone were produced by hydrogen-induced deformation twins impinging on grain boundaries and carbides. These results suggest a new mechanism of the acceleration of fatigue crack growth rates in high-strength steels caused by hydrogen-induced deformation twins, rather than due to hydrogen- enhanced localized plasticity. The phenomena associated with time dependent fatigue crack growth are presumed to be correlated with the initiation and coalescence of secondary cracks in the presence of hydrogen.

Hydrogen transport in solution-treated and pre-strained austenitic stainless steels and its role in hydrogen-enhanced fatigue crack growth

Hydrogen solubility and diffusion in Type 304, 316L and 310S austenitic stainless steels exposed to high-pressure hydrogen gas has been investigated. The effects of absorbed hydrogen and strain-induced martensite on fatigue crack growth behaviour of the former two steels have also been measured. In the pressure range 10–84 MPa, the hydrogen permeation of the stainless steels could be successfully quantified using Sieverts' law modified by using hydrogen fugacity and Fick's law. For the austenitic stainless steels, hydrogen diffusivity was enhanced with an increase in strain-induced martensite. The introduction of dislocation and other lattice defects by pre-straining increased the hydrogen concentration of the austenite, without affecting diffusivity. It has been shown that the coupled effect of strain-induced martensite and exposure to hydrogen increased the growth rate of fatigue cracks.

The effect of sensitization on the hydrogen-enhanced fatigue crack growth of two austenitic stainless steels

Fatigue crack growth tests were performed to evaluate the susceptibility to hydrogen-enhanced crack growth of AISI 304 and 316 stainless steels (SSs). Sensitization treatment at 650 °C 100 h played little effect on the fatigue crack growth behavior in air, regardless of testing specimens. However, hydrogen accelerated the fatigue crack growth of various specimens to different degrees; sensitized specimens were more susceptible as compared with the un-sensitized ones. Fatigue fracture appearance of various specimens tested in air exhibited mainly transgranular fatigue fracture together with rarely intergranular fracture and twin boundary separation. Meanwhile, intergranular fracture was found for sensitized specimens tested in hydrogen. Extensive quasi-cleavage fracture related to the strain-induced martensite accounted for the hydrogen-accelerated fatigue crack growth of unstable austenitic SSs. On the other hand, the lower susceptibility of 316H specimens could be attributed to the partial austenite transformation, as evidenced by a mixture of transgranular fracture feature and quasi-cleavage.

Effect of austenite instability on the hydrogen-enhanced crack growth of austenitic stainless steels

Fatigue crack growth tests were performed to assess the fatigue behavior of AISI 316L and 254 SMO stainless steels (SSs) in air and gaseous hydrogen. 254 SMO SS generally exhibited a greater resistance to fatigue crack growth than 316L. Sensitization treatment had only a marginal effect on the fatigue crack growth behavior of both alloys in air. Moreover, 316L SS exhibited significant hydrogen-enhanced crack growth but 254 SMO, even sensitized 254 SMO specimens, did not. A thin layer of strain-induced martensite was formed on the fatigue-fractured surface of the 316L SS, and its content increased when raising the stress ratio. The thin martensite layer was responsible for the hydrogen-enhanced fatigue crack growth of the 316L SS. By contrast, the extremely stable austenite was responsible for the low susceptibility of 254 SMO SS to hydrogen-accelerated crack growth. The trapping of hydrogen at the grain boundaries and the transformed martensite in the sensitized 316L specimens led to increased fatigue crack growth rates and intergranular fracture of the material.

Fatigue crack growth behavior of laser-annealed IN 718 alloy in hydrogen

The effect of hydrogen embrittlement on the fatigue crack growth of IN 718 plate and laser-annealed specimens in hydrogen containing environment were investigated. Although the differences in tensile strength and impact toughness between solution-annealed (S) and aged (A) IN 718 specimens were significant, the experimental results indicated that both specimens within the low Δ K regime exhibited a similar fatigue behavior. As the Δ K increased above 30 MPa m , the solution-annealed specimen revealed a higher fatigue crack growth rate (FCGR) than the aged one. In general, the IN 718 alloy had a low sensitivity to hydrogen-enhanced fatigue crack growth, independent of hydrogen sources. Residual compressive stresses ahead of the crack tip were responsible for the improved resistance to fatigue crack growth in a laser-annealed specimen. For alloys with similar strength, IN 718 alloy trapped a huge amount of hydrogen in the matrix showing a less susceptibility to hydrogen-enhanced fatigue crack growth in comparison with the maraging steel. Additionally, fatigue-fractured appearance near crack initiation sites reveals quasi-cleavage fracture in embrittled specimens.

Hydrogen-enhanced fatigue crack growth of Alloy 600

The fatigue crack growth (FCG) behavior of mill annealed Alloy 600 in 0.1 M NaCl solution, 25 °C, was studied by a fracture mechanics test method. The rates of FCG were affected by the applied cathodic potential, load frequency f, and load ratio R (R = Pmax/Pmax). At an applied cathodic potential of −1300 mVSCE, the FCG rates increased with decreasing load frequency and increasing load ratio. In comparison with the FCG rate in air, the FCG rate of Alloy 600 was enhanced at −1300 mVSCE in 0.1 M NaCl solution, 25 °C. The enhancement increased with decreasing load frequency, and the trend was more pronounced as the load ratio increased. However, the enhancement showed saturation behavior for lower load frequencies at R = 0.2 and 0.5, and a reverse trend was even found at R = 0.5. The fractographs of Alloy 600 fatigued at cathodic potential showed a brittle fracture mode. The enhancement of the FCG rates of Alloy 600 in 0.1 M NaCl solution, 25 °C, at −1300 mVSCE was probably due to hydrogen-assisted cracking. The critical load frequency fcr, which could induce a significant FCG rate enhancement, was identified, and the value of fcr was found to increase with increasing load ratio. At R = 0.5, the peak load frequency (about 0.03 Hz) that could result in the largest FCG rate was found. A possible mechanism for the effect of hydrogen-assisted cracking on the FCG rate enhancement is discussed in this paper.

Hydrogen-enhanced fatigue crack growth in Ti-6242S

The influence of hydrogen on the elevated-temperature fatigue-crack-growth kinetics of Ti-6Al-2Sn-4Zr-2Mo-0.1Si (Ti-6242S) was studied as a function of temperature, using a fracture-mechanics approach. At temperatures above 420 K, the effect of hydrogen on the fatigue-crack-growth rate in Ti-6242S greatly diminishes, but the rate in 530 wppm hydrogen-charged material remains 35% greater than that of the as-received material. Hydrogen diffusion through the continuous beta-phase in Ti-6242S is apparently the rate-controlling process for the internal-hydrogen-enhanced fatigue crack growth. In the high-temperature region (> 670 K), because creep deformation becomes dominant, the effect of internal hydrogen on the fatigue crack growth is significantly reduced and is negligible above 720 K.

Hydrogen-enhanced fatigue crack growth in Ti-6Al-4V ELI weldments

The effects of a hydrogen environment on the fatigue crack growth rates in Ti-6A1-4V ELI (STA) and weld material were determined in the temperature range of ambient to -200°F. The hydrogen environment resulted in an acceleration of the crack growth rate and a change in the fracture mode for both materials in the temperature range of ambient to -100°F. At -200°F, there was no significant difference between the crack growth rates obtained in helium and hydrogen gas. The degree of hydrogen-enhanced crack growth was found to be dependent on the crack tip stress-intensity range, temperature, and microstructure of the material. The data is consistent with an embrittlement mechanism involving hydrogen diffusing ahead of the crack front.