Hisao Matsunaga

Pressure Cycle Testing of Cr–Mo Steel Pressure Vessels Subjected to Gaseous Hydrogen

Pressure cycle tests were performed on two types of Cr–Mo steel pressure vessels with notches machined on their inside under hydrogen-gas pressures, between 0.6 and 45 MPa at room temperature. Fatigue crack growth (FCG) and fracture toughness tests of the Cr–Mo steels samples from the vessels were also carried out in gaseous hydrogen. The Cr–Mo steels showed accelerated FCG rates in gaseous hydrogen compared to ambient air. The fracture toughness of the Cr–Mo steels in gaseous hydrogen was significantly smaller than that in ambient air. Four pressure vessels were tested with gaseous hydrogen. All pressure vessels failed by leak-before-break (LBB). The LBB failure of one pressure vessel could not be estimated by using the fracture toughness in gaseous hydrogen KIC,H; accordingly, the LBB assessment based on KIC,H is conservative and there is a possibility that KIC,H does not provide a reasonable assessment of LBB. In contrast, the fatigue lives of all pressure vessels could be estimated by using the accelerated FCG rates in gaseous hydrogen.

Three lateral osteotomy designs for bilateral sagittal split osteotomy: biomechanical evaluation with three-dimensional finite element analysis

BackgroundThe location of the lateral osteotomy cut during bilateral sagittal split osteotomy (BSSO) varies according to the surgeons preference, and no consensus has been reached regarding the ideal location from the perspective of biomechanics. The purpose of this study was to evaluate the mechanical behavior of the mandible and screw-miniplate system among three lateral osteotomy designs for BSSO by using three-dimensional (3-D) finite element analysis (FEA).MethodsThe Trauner-Obwegeser (TO), Obwegeser (Ob), and Obwegeser-Dal Pont (OD) methods were used for BSSO. In all the FEA simulations, the distal segments were advanced by 5 mm. Each model was fixed by using miniplates. These were applied at four different locations, including along Champys lines, to give 12 different FEA miniplate fixation methods. We examined these models under two different loads.ResultsThe magnitudes of tooth displacement, the maximum bone stress in the vicinity of the screws, and the maximum stress on the screw-miniplate system were less in the OD method than in the Ob and TO methods at all the miniplate locations. In addition, Champys lines models were less than those at the other miniplate locations.ConclusionsThe OD method allows greater mechanical stability of the mandible than the other two techniques. Further, miniplates placed along Champys lines provide greater mechanical advantage than those placed at other locations.

A New Fatigue Testing Machine for Investigating the Behavior of Small Shear-Mode Fatigue Cracks

The investigation of the behavior of small shear-mode fatigue cracks in the high-cycle fatigue regime is essential to understand the mechanism of rolling-contact fatigue failures, such as flaking in bearings and shelling in rails, from the fracture mechanics point of view. The stable growth of a shear-mode fatigue crack was achieved by applying static compression to a specimen in a cyclic torsion fatigue test. This loading condition is usually obtained by a combined tension-torsion testing machine with a servo-hydraulic control system. In this study, a new testing machine was developed and found to be superior to the servo-hydraulic testing machine in terms of price, operation/maintenance costs, operating speed, and installation volume. For substantiation and demonstration purposes, a shear-mode fatigue crack growth test with a bearing steel was also carried out using both the new and the conventional servo-hydraulic testing machines. The experiments revealed that under the same loading conditions, nonpropagating shear-mode cracks of similar size and geometry could be obtained by the respective testing machines. Thus, it was concluded that the new testing machine has equivalent capabilities to the servo-hydraulic testing machine in performing shear-mode fatigue crack growth tests.

SSRT and fatigue crack growth properties of high-strength austenitic stainless steels in high-pressure hydrogen gas

Slow strain rate tests (SSRTs) were performed with two types of high-strength austenitic stainless steels, Types AH and BX, as well as with two types of conventional austenitic stainless steels, Types 304 and 316L. The tests used the following combinations of specimen types and test atmospheres: (i) non-charged specimens tested in air, (ii) hydrogen-charged specimens tested in air (tests for internal hydrogen), and (iii) non-charged specimens tested in hydrogen gas at pressures of 78 ∼ 115 MPa (tests for external hydrogen). Type 304 exhibited a marked reduction of ductility in the tests for both internal hydrogen and external hydrogen, whereas Types AH, BX and 316L exhibited little or no degradation. In addition, fatigue crack growth (FCG) tests for the four types of steels were also carried out in air and hydrogen gas at pressures of 100 ∼ 115 MPa. In Type 304, FCG in hydrogen gas was more than 10 times as fast as that in air, whereas the acceleration rate remained within 1.5 ∼ 3 times in Types AH, BX and 316L. It was presumed that, in Types AH and BX, a small amount of additive elements, e.g. nitrogen and niobium, increased the strength as well as the stability of the austenitic phase, which thereby led to the excellent resistance against hydrogen.Copyright

Comprehensive Understanding of Ductility Loss Mechanisms in Various Steels with External and Internal Hydrogen

Hydrogen-induced ductility loss and related fracture morphologies are comprehensively discussed in consideration of the hydrogen distribution in a specimen with external and internal hydrogen by using 300-series austenitic stainless steels (Types 304, 316, 316L), high-strength austenitic stainless steels (HP160, XM-19), precipitation-hardened iron-based super alloy (A286), low-alloy Cr-Mo steel (JIS-SCM435), and low-carbon steel (JIS-SM490B). External hydrogen is realized by a non-charged specimen tested in high-pressure gaseous hydrogen, and internal hydrogen is realized by a hydrogen-charged specimen tested in air or inert gas. Fracture morphologies obtained by slow-strain-rate tensile tests (SSRT) of the materials with external or internal hydrogen could be comprehensively categorized into five types: hydrogen-induced successive crack growth, ordinary void formation, small-sized void formation related to the void sheet, large-sized void formation, and facet formation. The mechanisms of hydrogen embrittlement are broadly classified into hydrogen-enhanced decohesion (HEDE) and hydrogen-enhanced localized plasticity (HELP). In the HEDE model, hydrogen weakens interatomic bonds, whereas in the HELP model, hydrogen enhances localized slip deformations. Although various fracture morphologies are produced by external or internal hydrogen, these morphologies can be explained by the HELP model rather than by the HEDE model.

Fatigue-life and leak-before-break assessments of CR-MO steel pressure vessels with high-pressure gaseous hydrogen

Pressure cycle tests were performed on two types of Cr-Mo steel pressure vessels with inner diameters of 306 mm and 210 mm and notches machined on their inside under hydrogen-gas pressures, varied between 0.6 and 45 MPa at room temperature. One of the Cr-Mo steels had a fine microstructure with tensile strength of 828 MPa, while the other had a coarse microstructure with tensile strength of 947 MPa. Fatigue-crack growth (FCG) and fracture-toughness tests of the Cr-Mo steels were also carried out in gaseous hydrogen. The Cr-Mo steels showed accelerated FCG rates in gaseous hydrogen compared to ambient air with an upper bound corresponding to an approximately 30-times higher FCG rate. Furthermore, in gaseous hydrogen, the fracture toughness of the Cr-Mo steel with coarse microstructure was significantly smaller than that of the steel with fine microstructure. Four pressure vessels were tested; then, all of the pressure vessels failed by leak-before-break (LBB). Based on the fracture-mechanics approach, the LBB failure of one pressure vessel could not be estimated by using the fracture toughness in gaseous hydrogen. The fatigue lives could be estimated by using the upper bound of the accelerated FCG rates in gaseous hydrogen.Copyright

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’.

Ductility Loss in Ductile Cast Iron with Internal Hydrogen

Hydrogen-induced ductility loss in ductile cast iron (DCI) was studied by conducting a series of tensile tests with three different crosshead speeds. By utilizing the thermal desorption spectroscopy and the hydrogen microprint technique, it was found that most of the solute hydrogen was diffusive and mainly segregated at the graphite, graphite/matrix interface zone, and the cementite of pearlite in the matrix. The fracture process of the non-charged specimen was dominated by the ductile dimple fracture, whereas that of the hydrogen-charged specimen became less ductile because of the accompanying interconnecting cracks between the adjacent graphite nodules. Inside the hydrogen-charged specimen, the interspaces generated by the interfacial debonding between graphite and matrix are filled with hydrogen gas in the early stage of the fracture process. In the subsequent fracture process, such a local hydrogen gas atmosphere coupled with a stress-induced diffusion attracts hydrogen to the crack tip, which results in a time-dependent ductility loss.

Effect of Occasional Shear Loading on Fatigue Crack Growth in 7075 Aluminum Alloy

Effect of occasional mode II loading on subsequent mode I fatigue crack growth behavior was investigated by using a thin-walled tube made of 7075-T6511 aluminum alloy. Careful observation of crack growth behavior revealed that the occasional mode II loading has two contradictory effects for crack growth behavior. The first is a retardation effect that is associated with the plastic deformation near crack tip. However, this effect is negligibly small for the crack growth life as a whole. The second is an acceleration effect caused by mode II fatigue crack growth itself. It was found that under relatively high ΔK level, the mode II crack growth was about an order magnitude faster than mode I crack growth. Therefore, to properly evaluate the effect of occasional shear loading in the 7075 alloy, the mode II crack growth should be taken into account.

Crack Size Dependency of Shear-Mode Fatigue Crack Threshold in Bearing Steel

Semi-elliptical shear-mode fatigue cracks were promoted in the axial direction of round specimens of SAE52100 bearing steel by fully-reversed cyclic torsion tests under a static axial compressive stress. Non-propagating cracks smaller than 1 mm were obtained in two ways; (i) stress amplitude decreasing tests of notched specimens, or (ii) constant stress amplitude tests of smooth specimens. The threshold stress intensity factor ranges, (KIIth and (KIIIth, showed a crack size dependency.