scholarly journals Fatigue Crack Growth Behaviour of High Strength Ferritic Steels in High Pressure Hydrogen

2018 ◽  
Vol 165 ◽  
pp. 03008
Author(s):  
Ashok Saxena ◽  
Kevin Nibur
Keyword(s):  
High Pressure ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Hydrogen Pressure ◽  
Gaseous Hydrogen ◽  
Loading Frequency ◽  
Crack Growth Rates ◽  
Pressure Hydrogen

The design of safe and low-cost, high-pressure hydrogen storage systems are a critical need for harnessing clean power but must consider the propensity of hydrogen to accelerate fatigue crack growth rates in the construction materials. Design of safe pressure vessels needs robust models for predicting crack growth rates and how they are affected by variables such as loading frequency, load ratios, hydrogen pressure, gaseous impurities, temperature, and material variability. In this study, fatigue crack growth rates were measured in the liner material in 10 MPa gaseous hydrogen at various load ratios, R, in the range -1 ≤ R ≤ 0.2. The effects of varying loading frequency were investigated, and the results were pooled with those from literature for similar alloys tested in 103 MPa gaseous hydrogen pressure. The differences in crack growth rates between H2 pressures of 10 to 103 MPa as well as the effects of frequency on the environment assisted crack growth rates were assessed. Loading frequency effects tend to saturate at frequencies of 1 Hz and less. H2 pressure effects appear to saturate at pressures of 45MPa, while load ratio effects are not significant for –1 ≤ R ≤ 0.2 but become important for R ≥ 0.2.

scholarly journals Measuring Fatigue Crack Growth Behavior of Ferritic Steels Near Threshold in High Pressure Hydrogen Gas

2020 ◽  
Author(s):  
Joseph Ronevich ◽  
Chris San Marchi ◽  
Kevin A. Nibur ◽  
Paolo Bortot ◽  
Gianluca Bassanini ◽  
...  
Keyword(s):  
High Pressure ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Pressure Vessels ◽  
Hydrogen Gas ◽  
Crack Growth Behavior ◽  
Crack Growth Rates ◽  
Pressure Hydrogen

Abstract Following the ASME codes, the design of pipelines and pressure vessels for transportation or storage of high-pressure hydrogen gas requires measurements of fatigue crack growth rates at design pressure. However, performing tests in high pressure hydrogen gas can be very costly as only a few laboratories have the unique capabilities. Recently, Code Case 2938 was accepted in ASME Boiler and Pressure Vessel Code (BPVC) VIII-3 allowing for design curves to be used in lieu of performing fatigue crack growth rate (da/dN vs. ΔK) and fracture threshold (KIH) testing in hydrogen gas. The design curves were based on data generated at 100 MPa H2 on SA-372 and SA-723 grade steels; however, the data used to generate the design curves are limited to measurements of ΔK values greater than 6 MPa m1/2. The design curves can be extrapolated to lower ΔK (< 6 MPa m1/2), but the threshold stress intensity factor (ΔKth) has not been measured in hydrogen gas. In this work, decreasing ΔK tests were performed at select hydrogen pressures to explore threshold (ΔKth) for ferritic-based structural steels (e.g. pipelines and pressure vessels). The results were compared to decreasing ΔK tests in air, showing that the fatigue crack growth rates in hydrogen gas appear to yield similar or even slightly lower da/dN values compared to the curves in air at low ΔK values when tests were performed at stress ratios of 0.5 and 0.7. Correction for crack closure was implemented, which resulted in better agreement with the design curves and provide an upper bound throughout the entire ΔK range, even as the crack growth rates approach ΔKth. This work gives further evidence of the utility of the design curves described in Code Case 2938 of the ASME BPVC VIII-3 for construction of high pressure hydrogen vessels.

scholarly journals Measurement of Fatigue Crack Growth Rates for SA-372 Gr. J Steel in 100 MPa Hydrogen Gas Following Article KD-10

2013 ◽  
Author(s):  
Brian Somerday ◽  
Chris San Marchi ◽  
Kevin Nibur
Keyword(s):  
High Pressure ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Pressure Vessels ◽  
Hydrogen Gas ◽  
Design Life ◽  
Crack Growth Rates ◽  
Pressure Hydrogen

The objective of this work is to enable the safe design of hydrogen pressure vessels by measuring the fatigue crack growth rates of ASME code-qualified steels in high-pressure hydrogen gas. While a design-life calculation framework has recently been established for high-pressure hydrogen vessels, a material property database does not exist to support the analysis. This study addresses such voids in the database by measuring the fatigue crack growth rates for three heats of ASME SA-372 Grade J steel in 100 MPa hydrogen gas at two different load ratios (R). Results show that fatigue crack growth rates are similar for all three steel heats and are only a mild function of R. Hydrogen accelerates the fatigue crack growth rates of the steels by at least an order of magnitude relative to crack growth rates in inert environments. Despite such dramatic effects of hydrogen on the fatigue crack growth rates, measurement of these properties enables reliable definition of the design life of steel hydrogen containment vessels.

scholarly journals Technical Basis for Master Curve for Fatigue Crack Growth of Ferritic Steels in High-Pressure Gaseous Hydrogen in ASME Section VIII-3 Code

2019 ◽  
Author(s):  
Chris San Marchi ◽  
Joseph Ronevich ◽  
Paolo Bortot ◽  
Yoru Wada ◽  
John Felbaum ◽  
...  
Keyword(s):  
High Pressure ◽  
Tensile Strength ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Pressure Vessel ◽  
Master Curve ◽  
Gaseous Hydrogen ◽  
Section Viii ◽  
Crack Growth Rates

Abstract The design of pressure vessels for high-pressure gaseous hydrogen service per ASME Boiler and Pressure Vessel Code Section VIII Division 3 requires measurement of fatigue crack growth rates in situ in gaseous hydrogen at the design pressure. These measurements are challenging and only a few laboratories in the world are equipped to make these measurements, especially in gaseous hydrogen at pressure in excess of 100 MPa. However, sufficient data is now available to show that common pressure vessel steels (e.g., SA-372 and SA-723) show similar fatigue crack growth rates when the maximum applied stress intensity factor is significantly less than the elastic-plastic fracture toughness. Indeed, the measured rates are sufficiently consistent that a master curve for fatigue crack growth in gaseous hydrogen can be established for steels with tensile strength less than 915 MPa. In this overview, published reports of fatigue crack growth rate data in gaseous hydrogen are reviewed. These data are used to formulate a two-part master curve for fatigue crack growth in high-pressure (106 MPa) gaseous hydrogen, following the classic power-law formulation for fatigue crack growth and a term that accounts for the loading ratio (R). The bounds on applicability of the master curve are discussed, including the relationship between hydrogen-assisted fracture and tensile strength of these steels. These data have been used in developing ASME VIII-3 Code Case 2938. Additionally, a phenomenological term for pressure can be added to the master curve and it is shown that the same master curve formulation captures the behavior of pressure vessel and pipeline steels at significantly lower pressure.

scholarly journals Orientation Dependence of Hydrogen Accelerated Fatigue Crack Growth Rates in Pipeline Steels

2018 ◽  
Author(s):  
Eun Ju Song ◽  
Joseph A. Ronevich
Keyword(s):  
Growth Rate ◽  
Fatigue Crack ◽  
Crack Growth Rate ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Fatigue Crack Growth Rate ◽  
Growth Rates ◽  
Orientation Dependence ◽  
Gaseous Hydrogen ◽  
Crack Growth Rates

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.

Cohesive Zone Modeling of Hydrogen Assisted Cracking in a 15-5 PH Steel and Comparison With Experiments

2015 ◽  
Author(s):  
Giovambattista Bilotta ◽  
Mandana Arzaghi ◽  
Gilbert Hénaff ◽  
Guillaume Benoit ◽  
Clara Moriconi ◽  
...  
Keyword(s):  
Crack Growth ◽  
Growth Rates ◽  
Cohesive Zone ◽  
Hydrogen Pressure ◽  
Crack Tip ◽  
Gaseous Hydrogen ◽  
Zone Model ◽  
Loading Frequency ◽  
High Hydrogen ◽  
Crack Growth Rates

Gaseous hydrogen substantially reduces fracture properties such as threshold stress intensity factor and crack growth resistance in the precipitation-hardened martensitic stainless steel investigated in this study. Fatigue crack propagation tests were performed on CT specimens under different atmospheres (hydrogen pressures from 0.09 to 40 MPa) on the Hycomat test bench, at the Pprime Institute in Poitiers, France. A strongly enhanced crack growth regime was identified at high hydrogen pressure and low-frequency loading. Crack growth rates obtained at a constant load under same pressure levels suggest that a combination of tensile stresses above a threshold (KIscc) and fatigue cycles contribute to the hydrogen embrittlement at the crack tip. These experimental results were compared to the finite element simulation results obtained by a recently developed cohesive zone model at the crack tip. A specifically developed traction-separation law which is suitable to describe the gradual degradation of cohesive stresses under monotonic and cyclic loadings, and which is furthermore sensitive to the hydrogen concentration was used. The effects of the different testing conditions, in terms of loading frequency and hydrogen pressure, on the modeling results are discussed. It was shown that the model qualitatively predicts the detrimental influence of gaseous hydrogen on the crack growth rates.

Measurement of Fatigue Crack Growth Rates for Steels in Hydrogen Storage

2009 ◽  
Author(s):  
Yoru Wada ◽  
Kouichi Takasawa ◽  
Ryoji Ishigaki ◽  
Yasuhiko Tanaka ◽  
Tadao Iwadate
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Crack Depth ◽  
Load Ratio ◽  
Gaseous Hydrogen ◽  
Test Machine ◽  
Critical Crack ◽  
Crack Growth Rates

Fatigue crack growth rates (da/dN) in up to 90MPa high-pressure gaseous hydrogen environments of quenched and tempered low alloy Cr-Mo steel: JIS-SCM435 with ultimate tensile strength level of 950MPa were measured utilizing a cycle, ranging from 0.3sec from 1000sec long with a road ratio R = 0.1. The longer cycle time tests (15sec to 1000sec per cycle) were conducted utilizing internal pressure test apparatus by utilizing cylinder (= CY) specimens, while shorter cycle (0.3sec to 25sec per cycle) tests were performed utilizing fatigue test machine using compact tension (= C(T)) specimens. Crack depth of CY specimens were measured by Time Of Flight Diffraction (TOFD) technique and the crack length of C(T) specimens were measured by compliance technique. Both C(T) and CY specimen showed accelerated sub-critical crack growth in gaseous hydrogen compared that in air or inert gas atmosphere. The effect of load ratio was also evaluated.

The Effect of Cyclic Loading Frequency on Corrosion-Fatigue Crack Growth in High-Strength Riser Materials

2010 ◽  
Author(s):  
Stephen J. Hudak ◽  
James H. Feiger ◽  
Jason A. Patton
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Corrosion Fatigue ◽  
Growth Rates ◽  
High Strength ◽  
Loading Frequency ◽  
Corrosion Fatigue Crack ◽  
Corrosion Fatigue Crack Growth ◽  
Crack Growth Rates

Corrosion-fatigue is a significant design consideration in deepwater floating production systems. Mechanical loading is accentuated due to the compliant nature of these structures, and sour service conditions can also occur either due to the nature of the crude production or due to seawater flooding of the reservoir to enhance production yield. New high-strength riser steels have recently been developed to meet the demands of deepwater development. The objective of this study was to characterize the corrosion-fatigue resistance of these materials in terms of crack growth rates as a function of applied stress intensity factor range (ΔK), as well as cyclic loading frequency. Experiments were performed on five different steels with yield strengths ranging from 848 to 1080 MPa. Two environments were considered: seawater with cathodic protection to simulate the environment outside of the riser, and a sour brine environment with low oxygen (< 10 ppb) to simulate the environment inside the riser. Not all steels were tested in the sour brine environment since not all were designed to operate in sour service. For both environments, higher strength steels were found to exhibit higher growth rates and lower saturation frequencies. Fatigue crack growth rates as a function of ΔK were also measured, and exhibited two different frequency responses. At high ΔK, the classical frequency response occurred: decreased frequency gave increased crack growth rates. At low ΔK, an inverse frequency effect was observed: deceased frequency gave decreased crack growth rates, as well as increased corrosion-fatigue crack growth thresholds. These differences are believed to be caused by different underlying processes controlling crack growth — specifically, material-environment reaction kinetics at high ΔK, and crack closure due to corrosion-product wedging at low ΔK. The practical significance of these results is discussed, including selection of frequencies for corrosion-fatigue crack growth testing, and applicability of results to structural integrity assessments.

Hydrogen Induced Intergranular Failure in Armco Iron Under Fatigue Crack Propagation

2016 ◽  
Author(s):  
Giovambattista Bilotta ◽  
Mandana Arzaghi ◽  
Gilbert Hénaff ◽  
Guillaume Benoit ◽  
Damien Halm
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Propagation ◽  
Crack Growth ◽  
Fatigue Crack Propagation ◽  
Hydrogen Pressure ◽  
Armco Iron ◽  
Gaseous Hydrogen ◽  
Loading Frequency ◽  
Intergranular Failure

Hydrogen generally results in a degradation of fatigue crack growth resistance in metals depending on the nature of the hydrogen interaction with crystalline defects developed during a cyclic loading. In this paper we present the first results regarding the characterization of the microstructure and the mechanical properties of Armco Iron with a ferritic microstructure, and the investigation of embrittlement under gaseous hydrogen environment. For this purpose, fatigue crack propagation tests were performed on CT40 specimens under high pressure gaseous hydrogen using Hycomat test bench, at the Pprime Institute in Poitiers. The fatigue crack growth rate data obtained so far at the 35 MPa of hydrogen pressure and at loading frequency of 20 Hz indicate a sharp increase in crack growth rates in a narrow range of stress intensity factor amplitudes. Also, it was observed that by decreasing the loading frequency to 2 or 0.2 Hz at the above mentioned hydrogen pressure no significant change in this transition regime happens. Scanning electron microscope observations of the fracture surfaces are used to support the explanations proposed for the hydrogen inducted intergranular failure in this material.

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