Hydrogen-induced Cracking Research Articles

An empirical model of the kinetics of hydrogen-induced cracking in pipeline steel, using statistical distribution models and considering microstructural characteristics and hydrogen diffusion parameters

This study proposes an empirical model to predict the kinetics of hydrogen-induced cracking (HIC) growth rate in pipeline steels based on experimentally measured hydrogen diffusion parameters and spatial distribution of microstructural features previously identified to have a role on HIC kinetics. In the experimental work, the HIC was induced by electrochemical cathodic charging and the crack growth was monitored by ultrasonic inspection. Optical and scanning electron microscopy were used to determine the spatial distribution parameters of non-metallic inclusions, and the ferrite grain and second phase characteristics. The hydrogen microprint technique used to visualize hydrogen diffusion path in the microstructure and the hydrogen diffusion parameters were determined by hydrogen permeation tests. Results show that NMI shape affects HIC nucleation sites, using student's t-distribution, while ferrite grain characteristics affect HIC growth rates, with X70–2 and X56 steel plates recorded highest HIC growth rate. The Log-Normal distribution model, supported by statistical analysis, effectively predicts HIC growth rates compared with Weibull and Gamma distribution models.

Investigation of slug catcher vessel degradation by hydrogen sulfide (H2S) damage

Slug catchers offer effectively multiphase flow management in the field of oil and gas industry. critical equipment required for isolates and confines liquid, gases, and solid particles in slugs under environmental conditions that observed to incoming production stream. This work examines the case study that undergoes corrosion failure in vessels of slug catcher, concentrating on (H2S) damage, hardness, and microscopic corrosion in different locations. The methodology of this study involved visual inspections, hardness, and microscopic testing in order to evaluate the level of nature corrosion. The results refer that while the failure of corrosion pits present, there were not cracks, microcracks, stress corrosion cracking (SCC), or Hydrogen Induced Cracking (HIC) recognized in the structural of vessel. The structures of ferrite and pearlite of the HIC were presented in main components, and there are no cracks or microcracks detected.

Analysis of hydrogen-induced cracking mechanism in quenching and partitioning steels

Quenching and partitioning (Q&P) steels are extensively used in the automotive industry due to their exceptional strength and ductility. However, the impact of hydrogen embrittlement (HE) poses a huge challenge to the safe service of Q&P steels, highlighting the necessity to investigate the hydrogen-induced cracking mechanisms. This study investigates the hydrogen-induced failure mechanisms in Q&P steels through experiments and finite element simulations, focusing on microstructure, local stress heterogeneity, hydrogen distribution characteristics, and hydrogen-induced cracking. The results reveal that hydrogen cracking nucleation in Q&P steel is primarily due to the further accumulation of hydrogen in local high-stress martensitic/austenitic regions.

The adverse effect of grain refinement on hydrogen embrittlement in a high Mn austenitic steel

This study presents a novel observation wherein the reduction in grain size (GS) from 20 μm to 1 μm in austenitic steel adversely affects hydrogen embrittlement (HE). The findings indicate an increase in total absorbed hydrogen with grain refinement when subjected to cathodic hydrogen charging. The results demonstrate that even with grain refinement to 1 μm, the primary mode of hydrogen damage remains intergranular, with a significant increase in relative elongation loss (REL%). This phenomenon is attributed to the early nucleation of intergranular hydrogen-induced cracks (HICs) and the accelerated propagation rates of HICs, leading to local stress increments and rapid alloy failure. The accelerated development of HICs is ascribed to the impact of grain refinement on intensified normal stress exerted on grain boundary planes, as well as the suppression of ε-martensite and its positive effect on crack arresting. Besides the enhanced degradation rate of the hydrogen-affected area (HAA) due to grain refinement, the higher ratio of HAA to the entire cross-sectional area was identified as a crucial factor contributing to rapid failure and the inverse effect of grain refinement on HE resistance.

Hydrogen Embrittlement Behavior of API X70 Linepipe Steel under Ex Situ and In Situ Hydrogen Charging.

This study investigates the hydrogen embrittlement behavior of API X70 linepipe steel. The microstructure was primarily composed of a dislocation-rich bainitic microstructure and polygonal ferrite. Slow strain-rate tests (SSRTs) were performed under both ex situ and in situ electrochemical hydrogen charging conditions to examine the difference between hydrogen diffusion and trapping behaviors. The ex situ SSRTs showed almost the same tensile properties as air and a limited brittle fracture confined to near the surface. In contrast, the in situ SSRTs showed an abrupt failure after the maximum tensile load, leading to a brittle fracture across the entire fracture surface with stress-oriented hydrogen-induced cracking (SOHIC). The crack trace analysis results indicated that SOHIC propagation paths were influenced by localized hydrogen accumulation due to high-stress fields. As a result, the dominant hydrogen embrittlement mechanisms, such as hydrogen-enhanced localized plasticity (HELP) and hydrogen-enhanced decohesion (HEDE), changed. These findings provide critical insights into the microstructural factors affecting hydrogen embrittlement, which are essential for the design of hydrogen-resistant steels in hydrogen infrastructure applications.

Effect of V-Ti multi-microalloying on enhancing hydrogen embrittlement resistance in hot-stamping steel

Hydrogen embrittlement (HE) has become a significant concern that limits the usage of ultra-high strength hot-stamping steel. In this work, the utilization of a novel approach employing V-Ti multi-microalloying has yielded substantial improvements in the resistance of hot-stamping steel to HE. The experimental findings demonstrate that V-Ti multi-microalloying effectively restrained the coarsening of precipitates, leading to the generation of high-density nanosized (V, Ti) C complex precipitates. The first principle calculation results indicate that V-Ti multi-microalloying improved the hydrogen trapping capacity of (V, Ti) C compared with TiC. Additionally, this approach refined the prior austenite grain size, fortifying the material's resistance to hydrogen-induced cracking.

Research on the influence of finish rolling technique parameters on H2S corrosion resistance behavior of pipeline steel in the thickness direction

Abstract Natural gas was an important energy for human society’s development, and there was still a great demand for this type of energy. It required pipeline steel for energy transport and had excellent hydrogen-induced cracking resistance. Thermomechanical controlled processing (TMCP) was a frequently used manufacturing method for pipeline steel. It was necessary to research the effect of finish rolling technique parameters on the H2S corrosion resistance behavior of pipeline steel in the thickness direction, especially concerning microstructure and hardness in the thickness direction. So, for the research, optical microscope (OM), hydrogen-induced cracking tests (HIC), and hardness tests were used to study the effect of finish rolling technique parameters on H2S corrosion resistance. As finish rolling deformation increases, deformation can effectively conduct from surface to center and reduce the average hardness gap between the surface and the center. It can also generate finer microstructure and smaller hardness differentials from the thickness direction. All these can enhance the hydrogen-induced cracking resistance.

Enhanced corrosion resistance of a novel periodic multilayered Si/(Si, N)-DLC coating against simulated coal mine water

In this study, a novel periodic multilayered DLC coating, which was composed of a Si interlayer and a Si/N co-incorporated DLC layer (Si/(Si, N)-DLC) per period, was deposited; the corrosion behavior under the neutral, acidic, or alkaline coal mine water environment and its periodic number dependence, especially the fundamental corrosion mechanism, were systemically explored. Results suggest that compare to the substrate, the introduction of multilayered Si/(Si, N)-DLC coating presents a dramatic enhancement in the corrosion resistance under coal mine water environment. However, with increasing the periodic number, the corrosion resistance of the multilayered coating strongly depends on the working environment, which exhibits an enhancement in neutral and alkaline environments while a degeneration in acidic environment. This is attributed to not only the prolongation of the corrosion path caused by the multilayered structure but also the formation of an insulating silicon oxide layer in neutral and alkaline environments. However, in acidic environments, the strong permeability of H+ with the smallest ionic radius easily infiltrates the inherent defects of the coating. This not only weakens the protective properties of the multilayer structure but also leads to hydrogen-induced cracking, ultimately diminishing corrosion resistance. These findings theoretically guide the development of the DLC coatings with excellent corrosion resistance for coal mine applications.

High strength low alloy steel joint fabricated by laser welding with real-time high-frequency resistance heating

The balance between softening and hardening is still a great challenge for the laser welding of the high strength low alloy steel. For example, welding with low heat input was commonly used to avoid softening, but it would inversely harden the joint and introduce the undesired welding defects such as hydrogen-induced cracks. This work proposed a simple and robust processing technique, denominated High Frequency electric cooperated Laser Welding. Laser heat source was combined with high-frequency electric heat source to balance heat input distribution and reconcile the contradiction between softening and hardening in the welding of high strength low alloy steel. As a structural material sensitive to welding softening and hardening, S690QL steel was adopted to show the fundamental advancement of the new process. Benefitted from the skin effect and proximity effect of high-frequency current that improve the heat input distribution and the regulation of the high-frequency heat input proportion, the martensite content in the heat affected zone was greatly reduced, whilst the grain size was limited to a low value. Under the high-frequency heat input proportion of 47.1 %, lower bainite distributed throughout the heat affected zone. The softening and hardening issues of the joint therefore have been improved simultaneously: the tensile strength of the joint was almost equal to that of the base material, the impact energy of weld seam and the heat affected zone reached 77.6 J and 66.2 J respectively.

Temperature-dependent hydrogen-induced crack propagation behaviour and mechanism in polycrystalline α-iron: Insights from molecular dynamics simulations

Understanding the interactions between hydrogen and material integrity in polycrystalline α-Fe is essential for advancing the reliability of critical infrastructure and energy systems. In this study, molecular dynamics simulations were implemented to pinpoint the crack propagation behaviour and mechanism in polycrystalline α-Fe under various hydrogen concentrations and temperatures. The results show that a phase transition from body-centred cubic to face-centred cubic structure first occurs at the crack tip, followed by grain boundary-mediated plasticity activities at room temperature devoid of hydrogen. A limited amount of hydrogen atoms (H/Fe atomic ratio<1%) induces twinning emission from the tip, and increasing temperature further enhances dislocation plasticity as a consequence of decreased unstable stacking fault energy, thereby leading to the blunting of the crack tip. At high hydrogen concentrations (H/Fe atomic ratio>1%), the formed hydrides ahead of the crack tip suppress the phase transition, and concurrently temperature-enhanced dislocation plasticity disappears. As a consequence, the crack propagation proceeds via grain boundary cavity nucleation and growth, and ultimately evolves into intergranular fracture. These findings provide an atomistic-level explanation for temperature-dependent hydrogen-crack interaction mechanisms, and reveal a transition in the fracture mode from ductile transgranular to intergranular failure associated with locally high hydrogen concentrations found in the experiments.

Failure of a high-pressure flash gas pipeline from coal coke gasification to the cleaning section due to hydrogen-induced cracking

ABSTRACT The high-pressure flash pipeline of coal coke gasification leaked within one week after the operation. Further macroscopic observation showed that cracks appeared in the base material area near the weld. The medium transported by the pipe was low-concentration acid gas. Visual inspection, tensile testing, impact testing, chemical composition analysis, metallographic analysis, energy dispersive spectroscopy, X-ray diffraction analysis, and electron backscattering diffraction analysis were used to reveal the sources of cracks in the pipeline. It was found that the cracks were intergranular and filled with corrosion products. The chemical composition of the corrosion products is rich in Cr, S, and O. After the crack was opened, fracture features of ‘rock candy’ were observed, exhibiting brittle fracture characteristics. The cracks were caused by hydrogen-induced cracking along the grain boundary. On this basis, suggestions and countermeasures were put forward for the failure of the high-pressure flash gas pipeline.

Circular Economy Opportunity Utilizing Fitness for Service Methodology for Aged HIC Defected Reboiler

The phenomenon of Hydrogen-Induced Cracking (HIC) is a cracking mechanism of carbon steel material as in ASME SA- 516 pressure containing equipment operating in a wet sour H2S environment. Such phenomenon is mainly driven by the diffusion of hydrogen atoms into the carbon steel due to corrosion reaction. The Structural integrity of an in-service equipment that contain a flaw or damage such as HIC could be scrutinised using Fitness For Service (FFS) assessments as quantitative engineering evaluations. The assessments are conducted using methodologies specifically prepared for pressurized equipment. These assessments provide standard procedure that can be used to determine if pressurized equipment containing flaws could continue to operate safely for certain period of time. FFS assessments are recognized and referenced by the API Codes and Standards such as API- 510, 570, &amp; 653, and by National Board-23. Those assessments are considered suitable methodologies for evaluating the structural integrity of pressurized equipment as heat exchangers, pressure vessels, piping systems and storage tanks where inspection has revealed degradation and flaws in the equipment. The objective of this paper isto illustrate API-579 case study of HIC of fifty (50) years operating pressurized equipment, namely reboiler.

A phase field method for predicting hydrogen-induced cracking on pipelines

An accurate determination of the threshold conditions to initiate cracks on aged hydrogen pipelines is paramount for ensuring energy transport safety. In this work, a finite element-based phase field method was developed to assess the crack initiation on dented pipelines while considering the hydrogen (H) impact. Theoretical and multi-physics numerical formulas were derived for prediction of the elastic-plastic fracture behavior of H-contained steel. A critical phase field parameter, ϕ=0.69, is defined for predicting crack initiation at the dent on pipelines. The presence of H within the steel decreases the threshold dent depth for initiating H-induced cracks. When the initial H concentration increases from 0 to 0.5 wppm, the maximum dent depth for crack initiation reduces from 17.5 mm to 10.7 mm. The maximum dent depth required for crack initiation reduces from 17.5 mm to 7.8 mm when an internal pressure of 8 MPa is applied on the steel pipe. The site with the maximum phase field parameter changes during indentation, implying that the location initiating cracks depends on the dent dimension. The existing criteria in ASME B31.12 standard are not applicable for predicting H-induced crack initiation on dented pipelines. This study proposes a new method to predict hydrogen-induced cracking on aged pipelines when transporting hydrogen.

An Effective Barrier Coating Technology Against Premature Bolt Failures in Underground Mines

AbstractSignificant safety and economic consequences accompany the premature failure of bolts, posing sustainability challenges for mining operations. Previous studies have indicated that hydrogen-induced stress corrosion cracking (HISCC), primarily influenced by microbial activities termed microbiologically influenced stress corrosion cracking (MISCC), stands as a major contributor to the premature failure of bolts in underground mines. Presently, an effective mechanism to mitigate these premature failures is lacking. In this study, multiple commercially available coatings undergo testing to assess their susceptibility and suitability in preventing HISCC and MISCC. Additionally, a purpose-developed coating is examined. The results reveal that the tested commercially available coatings either fail to prevent these types of corrosion or are unsuitable for the intricate conditions within underground mines. The laboratory results show the coating has a significant anti-acidic corrosion and anti-MISCC performance. Conversely, the coating formulated in this study successfully averts both MISCC and HISCC, proving its applicability within the complex geological environments prevalent in mines. This breakthrough offers a promising solution to mitigate premature bolt failures in complex underground geological environments. The developed coating presents a viable way forward for enhancing safety, reducing economic losses, and improving the overall sustainability of mining operations.

Enhanced hydrogen embrittlement resistance of additive manufacturing Ti-6Al-4V alloy with basket weave structure

The hydrogen embrittlement (HE) behavior of tungsten inert gas arc additive manufacturing (AM) Ti-6Al-4V alloy was studied through tensile tests with/without hydrogen charging. The influence of hydrogen on the microstructure and crack propagation of AM Ti-6Al-4V alloy was investigated. The results indicated that the AM Ti-6Al-4V alloy with a basket weave structure alleviated local stress at grain boundaries during deformation, thus avoiding intergranular cracking and brittle fracture. The AM alloy displayed less HE susceptibility than that of the wrought alloy, which was due to the basket weave structure hindering the propagation of hydrogen-induced cracks, thereby improving the HE resistance.

Guided analysis of fracture toughness and hydrogen-induced embrittlement crack growth rate in quenched-and-tempered steels using machine learning

This study focuses on developing a machine learning (ML) model, specifically a Bayesian-optimized deep neural network, leveraging numerical simulation data for the prediction of fracture toughness (KIC) and crack growth rate (CGR) in Quenched-and-Tempered Steel (AISI 4140 alloy) under hydrogen embrittlement conditions. The proposed model demonstrated superior accuracy with Root Mean Squared Error (RMSE) values of 0.052 for KIC and 0.084 for CGR, surpassing conventional ML models including random forest (0.094 for KIC, 0.139 for CGR), gradient boosting (0.184 for KIC, 0.196 for CGR), support vector regression (0.142 for KIC, 0.110 for CGR), and decision tree regression (0.119 for KIC, 0.133 for CGR). The findings also revealed that input parameters such as temperature, hydrogen concentration, and hydrostatic stress carry higher weight factors compared to other parameters in predicting KIC. Similarly, the prediction of high CGR values, ranging from 5.9 × 10−5 to 9.5 × 10−5 m/s, was associated with the importance of hydrostatic stress, strain rate, and initial crack length in the prediction model. This underscores the model's ability to capture the intricate dependencies of output objectives on input features. Furthermore, a comprehensive case study, informed by the ML model, highlights the potential for tuning specific processing input parameters to manage hydrogen embrittlement effectively, contributing to a deeper understanding of its dynamics.

Hydrogen-induced cracking of longitudinally submerged arc welded HSLA API 5L X65 carbon steel pipeline

This study investigates the hydrogen-induced cracking (HIC) of a thermomechanical controlled processed (TMCP) API 5L X65 steel pipe fabricated using the JCOE forming process. Despite passing HIC testing as a plate, the final pipe exhibited unexpected failure, highlighting the critical influence of pipe fabrication on material performance. In this study, failed pipes were subjected to heat treatment, and HIC testing following NACE TM 0284 standard, SEM, and EDX examinations. The effect of heat treatment on the grain size, residual stress and susceptibility to HIC was investigated. The findings revealed that welding played a detrimental role, as all the HIC failures occurred at the welded area (0° orientation) due to welding-induced stresses and potential microstructural changes. It is believed that the welding process imposed reversible hydrogen traps in the HIC resistance plate ultimately reducing the HIC resistance. The heat treatment proved an effective method for relieving the applied micro-residual stresses that resulted in enhanced HIC resistance of the material.

Microstructure Analysis and Fitness-for-Service Assessment of Hydrogen-Induced Cracking in an Amine Tower

Microstructure Analysis and Fitness-for-Service Assessment of Hydrogen-Induced Cracking in an Amine Tower

Crack propagation characteristics and fatigue life of the large austenitic stainless steel hydrogen storage pressure vessel

Hydrogen-induced cracking or embrittlement can have a substantial and severe impact on the fatigue life of large austenitic stainless steel hydrogen storage pressure vessels. In this study, a dynamic model for the plastic zone in the crack tip considering the hydrogen diffusion was established and a correction factor for the stress intensity factor of the hydrogen storage pressure vessel was proposed for 316L stainless steel, which is commonly used pressure vessel material. The crack propagation characteristics and fatigue life of the stainless steel vessel were investigated. The results indicated that the shortest fatigue life under hydrogen pressure occurs at the intersection of the vent nozzle and the vessel head. The hydrogen environment not only reduces vessel service life but also makes the influence of pressure on cracks propagation more pronounced. It leads to a significant reduction in the fatigue life of pressure vessels when overpressure happens during operation. These research findings are valuable for the accurate assessment of the vessel fatigue life and improving the quality of large hydrogen storage vessel structures.

Corrosion behavior of austenitic stainless steel and nickel-based welded joints in underwater wet welding

Marine structures such as ports, bridges, pipelines, vessels, and platforms are an essential part of modern infrastructure, where the use of higher-strength steel provides savings in logistics and construction. However, the repair of higher-strength steels can be challenging, especially underwater. Wet shielded metal arc welding is the most widely used and least expensive method for underwater welding repairs, but is very susceptible to hydrogen-induced cracking. Thus, researchers and welding engineers aim to reduce the amount of hydrogen in the weld material. Recent success has been achieved through the use of austenitic welding consumables, such as austenitic stainless steel and nickel-based electrodes. The use of these consumables drastically reduces the amount of diffusible hydrogen in the weld metal. However, these austenitic materials usually have different corrosion potential as compared to the structural steel the weld beads are applied to. This creates the risk of severe galvanic corrosion. In the presented study, the corrosion behavior of welds created with austenitic stainless steel and nickel-based electrodes were studied. Samples were aged for 1.5 years in the Baltic Sea. Simultaneously, the effectiveness of corrosion protection systems such as coating and Impressed Current Cathodic Protection (ICCP) were evaluated. Localized corrosion occurred in the heat-affected zone when austenitic electrodes were used in the corrosive environment. The localized corrosion depth after 1.5 years in the Baltic Sea and in the salt spray layer was approximately 250 µm and 390 µm, respectively. The ICCP system and the use of a coating were effective in preventing localized corrosion. The low pitting corrosion density of 2.5 × 103 m−2 corresponds to grade A1 according to the standard and was found to be negligible as compared to the localized corrosion in the heat-affect zone.