Fracture and Fatigue Tolerant Steel Pressure Vessels for Gaseous Hydrogen

2010 ◽  
Author(s):  
Kevin A. Nibur ◽  
Chris San Marchi ◽  
Brian P. Somerday
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Maximum Load ◽  
Pressure Vessels ◽  
Hydrogen Gas ◽  
R Ratio ◽  
History Of ◽  
Crack Growth Rates

Fatigue crack growth rates and rising displacement fracture thresholds have been measured for a 4130X steel in 45 MPa hydrogen gas. The ratio of minimum to maximum load (R-ratio) and cyclic frequency was varied to assess the effects of these variables on fatigue crack growth rates. Decreasing frequency and increasing R were both found to increase crack growth rate, however, these variables are not independent of each other. Changing frequency from 0.1 Hz to 1 Hz reduced crack growth rates at R = 0.5, but had no effect at R = 0.1. When applied to a design life calculation for a steel pressure vessel consistent with a typical hydrogen trailer tube, the measured fatigue and fracture data predicted a re-inspection interval of nearly 29 years, consistent with the excellent service history of such vessels which have been in use for many years.

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.

Fatigue Crack Growth Properties of 16MnR and 316L Steels at High Temperature

2005 ◽  
Author(s):  
Zengliang Gao ◽  
Weiming Sun ◽  
Weiya Jin ◽  
Ying Wang ◽  
Fang Zhang
Keyword(s):  
Fatigue Crack ◽  
High Temperature ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Fatigue Cracks ◽  
Pressure Vessels ◽  
Effect Of Temperature ◽  
Growth Properties ◽  
Crack Growth Rates

Fatigue failures often take place in high temperature pressure vessels and equipment because of fluctuation of pressure and temperature. Fatigue crack growth properties of materials at high temperatures are very important for safety assessment of high temperature equipment. A series of fatigue crack growth tests were carried out, and fatigue crack growth rates were determined at 25∼500°C for typical steels 316L and 16MnR. The laws of fatigue crack growth of two materials at different temperatures and the effect of temperature on fatigue crack growth rates were studied. The results show that the crack growth rates increase with temperature for 316L steel. Both the exponent n and constant C for Paris law change with temperature. The fatigue cracks of 16MnR propagate at 150 °C and 300 °C more slowly than at room temperature and 425 °C. The fatigue crack growth rate at 425 °C is the highest for temperature range of 25–425 °C.

scholarly journals Hydrogen Effects on Fatigue Crack Growth Rates in Pipeline Steel Welds

2016 ◽  
Author(s):  
Joe A. Ronevich ◽  
Brian P. Somerday
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Pipeline Steel ◽  
Hydrogen Gas ◽  
Friction Stir Weld ◽  
Friction Stir ◽  
Welding Processes ◽  
Crack Growth Rates

Fatigue crack growth rate (da/dN) versus stress intensity factor range (ΔK) relationships were measured for various grades of pipeline steel along with their respective welds in high pressure hydrogen. Tests were conducted in both 21 MPa hydrogen gas and a reference environment (e.g. air) at room temperature. Girth welds fabricated by arc welding and friction stir welding processes were examined in X65 and X52 pipeline grades, respectively. Results showed accelerated fatigue crack growth rates for all tests in hydrogen as compared to tests in air. Modestly higher hydrogen-assisted crack growth rates were observed in the welds as compared to their respective base metals. The arc weld and friction stir weld exhibited similar fatigue crack growth behavior suggesting similar sensitivity to hydrogen. A detailed study of microstructure and fractography was performed to identify relationships between microstructure constituents and hydrogen accelerated fatigue crack growth.

Characteristics of Corrosion Fatigue Crack Growth in Salt Water of Aluminum Alloys for Hydrogen Gas Containers

2013 ◽  
Author(s):  
Takeshi Ogawa ◽  
Yuki Sugiyama ◽  
Toshihiko Kanezaki ◽  
Noboru Hayashi
Keyword(s):  
Fatigue Crack ◽  
Aluminum Alloys ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Salt Water ◽  
Hydrogen Gas ◽  
Corrosion Fatigue Crack ◽  
Corrosion Fatigue Crack Growth ◽  
Crack Growth Rates

A hydrogen gas container is one of the critical components for fuel cell vehicles (FCV), which is expected for CO2-free personal transportation. In the early stage of commercial FCV, the major container structure will be a compressed hydrogen gas cylinder, which consists of metal or plastic linear with metal boss and carbon fiber reinforced plastics (CFRP). In order to choose an appropriate material for the metal boss and metal liner, corrosion resistance should be evaluated for various aspects such as corrosion fatigue crack growth (CFCG) and stress corrosion cracking (SCC) in the high pressure hydrogen as well as in salt water environment for the purpose of vehicle use. In the present study, CFCG characteristics were evaluated for several aluminum alloys in air and in salt waters with various concentrations. The results showed that the crack growth rates were accelerated in salt water for all the materials and their environmental sensitivities were compared. The concentrations of the salt water exhibited minor effect on the fatigue crack growth rates. These CFCG characteristics were compared with the corrosion test results based on the ISO 7866 Annex A [1]. A basic idea was proposed for the evaluation of compressed hydrogen gas containers and the important material properties were suggested.

scholarly journals Measurement of Fatigue Crack Growth Relationships in Hydrogen Gas for Pressure Swing Adsorber Vessel Steels

2015 ◽  
Vol 137 (2) ◽  
Author(s):  
Brian P. Somerday ◽  
Monica Barney
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Load Cycle ◽  
Hydrogen Gas ◽  
Stress Intensity Factor Range ◽  
Cycle Frequency ◽  
Pressure Swing ◽  
Crack Growth Rates

Hydrogen-assisted fatigue crack growth rates (da/dN) were measured for SA516 Grade 70 steel as a function of stress-intensity factor range (ΔK) and load-cycle frequency to provide life-prediction data relevant to pressure swing adsorber (PSA) vessels. For ΔK values up to 18.5 MPa m1/2, the baseline da/dN versus ΔK relationship measured at 1 Hz in 2.8 MPa hydrogen gas represents an upper bound with respect to crack growth rates measured at lower frequency. However, at higher ΔK values, baseline da/dN data must be corrected to account for modestly higher crack growth rates at the lower frequencies relevant to PSA vessel operation.

Influence of Environment and Creep on Fatigue Crack Growth in a High Temperature Aluminum Alloy 8009

1994 ◽  
Vol 116 (1) ◽  
pp. 45-53 ◽  
Author(s):  
K. V. Jata ◽  
D. Maxwell ◽  
T. Nicholas
Keyword(s):  
Growth Rate ◽  
Fatigue Crack ◽  
Crack Growth Rate ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Hold Time ◽  
Maximum Load ◽  
Frequency Effects ◽  
Crack Growth Rates

Frequency effects on fatigue crack growth rates are examined in aluminum alloy 8009 in sheet and extruded product forms. The investigations show that frequency effects on the fatigue crack growth rates are pronounced in the sheet but minimal in the extrusion. The influence of creep cracking on fatigue crack growth rate is studied through tests with a 60 s hold-time at maximum load at several stress intensity ranges. A 60 s hold-time at maximum load at 315°C tends to retard fatigue crack growth in both the sheet and the extrusion. The mechanism by which this retardation occurs is attributed to stress relaxation at the crack tip. At 204°C a 60 s hold at Pmax accelerates crack growth rate in the sheet but not in the extrusion. Vacuum and laboratory air tests show that fatigue crack growth rates in vacuum are lower than in air by about a factor of four. A 60 s hold-time at minimum load has only a minor effect on the fatigue crack growth rates at 315°C and no effect at 204°C, confirming the absence of any strong environmental contribution to crack growth rate. Fracture modes in fatigue, creep crack growth and hold-time at Pmax are significantly different. The fractographic results are discussed in relation to the mechanical property data.

scholarly journals Optimizing Measurement of Fatigue Crack Growth Relationships for Cr-Mo Pressure Vessel Steels in Hydrogen Gas

2015 ◽  
Author(s):  
Brian Somerday ◽  
Paolo Bortot ◽  
John Felbaum
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Upper Bound ◽  
Growth Rates ◽  
Hybrid Approach ◽  
Hydrogen Gas ◽  
Design Life ◽  
Pressure Vessel Steels ◽  
Crack Growth Rates

The objective of this study was to explore an approach for measuring fatigue crack growth rates (da/dN) for Cr-Mo pressure vessel steels in high-pressure hydrogen gas over a broad cyclic stress intensity factor (ΔK) range while limiting test duration, which could serve as an alternative to the method prescribed in ASME BPVC VIII-3, Article KD-10. Fatigue crack growth rates were measured for SA-372 Grade J and 34CrMo4 steels in hydrogen gas as a function of ΔK, load-cycle frequency (f), and gas pressure. The da/dN vs. ΔK relationships measured for the Cr-Mo steels in hydrogen gas at 10 Hz indicate that capturing data at lower ΔK is valuable when these relationships serve as inputs into design-life analyses of hydrogen pressure vessels, since in this ΔK range crack growth rates in hydrogen gas approach rates in air. The da/dN vs. f data measured for the Cr-Mo steels in hydrogen gas at selected constant-ΔK levels demonstrate that crack growth rates at 10 Hz do not represent upper-bound behavior, since da/dN generally increases as f decreases. Consequently, although fatigue crack growth testing at 10 Hz can efficiently measure da/dN over a wide ΔK range, these da/dN vs. ΔK relationships at 10 Hz cannot be considered reliable inputs into design-life analyses. A possible hybrid approach to efficiently establishing the fatigue crack growth rate relationship in hydrogen gas without compromising data quality is to measure the da/dN vs. ΔK relationship at 10 Hz and then apply a correction based on the da/dN vs. f data. The reliability of such a hybrid approach depends on adequacy of the da/dN vs. f data, i.e., the data are measured at appropriate constant-ΔK levels and the data include upper-bound crack growth rates.

Probabilistic Life Prediction of Hydrogen Steel Pressure Vessels in Industrial Electric Trucks

2014 ◽  
Author(s):  
Constantinos Minas ◽  
Sejalben Patel
Keyword(s):  
Fatigue Crack ◽  
Fuel Cell ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Pressure Vessel ◽  
Pressure Vessels ◽  
Hydrogen Gas ◽  
R Ratio ◽  
Two Samples ◽  
Number Of Cycles

Fuel cell powered industrial electric trucks are widely used in industry where more than 4000 systems are currently installed, achieving more than 20 million operating hours. The electric trucks are equipped with fuel cell power systems instead of an array of lead-acid batteries, which incorporate a permanently mounted pressure vessel containing compressed hydrogen gas and enabling onboard fueling. Fueling can be performed several times a day subjecting the pressure vessel to a large number of pressure cycles. It is critical to design the pressure vessel to withstand the required number of cycles which is in the thousands, over the life of the fuel cell power system estimated at 20000 hours. Steel pressure vessels which are subjected to hydrogen embrittlement are widely used in this application. In order to ensure the safety of the design, a linear elastic fracture mechanics model was developed in order to predict the life of the steel pressure vessel. The developed model was based on the ASME pressure vessel code section KD-10, which uses fatigue crack growth laws based on the relationship between the fatigue crack growth rate (da/dN) and the cyclic intensity factor (ΔK). Two samples were tested under hydrogen cyclic pressure loading. The experimental data was used to obtain estimates for the crack initiation phase. Statistical data was obtained from several hundred systems of the installed base, in order to determine the distributions of the maximum and minimum pressures the vessel is typically subjected to. The probabilistic LEFM model was used in a Monte Carlo simulation where the maximum and minimum pressure assumed a random value based on the equivalent random generator of their associated statistical distribution that is an extreme distribution and a Johnson SB distribution, respectively. The results indicated an increase by a factor of two, in the number of cycles when compared to the cycle prediction based on a constant R-ratio (maximum/minimum fill pressure). The analysis was repeated with normal distribution random generators which resulted in similar results. The results from this analysis ensure the safety of the steel pressure vessel design.

Analysis of the Effect of Load Ratio on Fatigue Crack Growth

2011 ◽  
Vol 181-182 ◽  
pp. 330-336 ◽  
Author(s):  
Ying Xiong
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Growth Rates ◽  
Multiaxial Fatigue ◽  
Cyclic Plasticity ◽  
Plasticity Model ◽  
R Ratio ◽  
Crack Growth Rates ◽  
Fatigue Criterion

In this paper, fatigue test and numerical simulation are carried out for Q345 weld joint under constant amplitude loading at different R-ratio using the compact tension samples with 3.8mm thickness. The result indicates that fatigue crack growth rates in the base metal is not sensitive to R-ratio, but the fatigue crack growth rates increases in the weld zone with R-ratio increasing. The effect of R-ratio on fatigue crack growth is analyzed based on J-S cycle plasticity model and Jiang’s multiaxial fatigue criterion. The finite element method (FEM) is used for the stress-strain analysis with the implementation of an accurate J-S cyclic plasticity model. With the detailed stresses and strains, fatigue damage assessment is made using a Jiang’s multiaxial fatigue criterion.

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