Kevin A. Nibur

Fracture and Fatigue of Commercial Grade API Pipeline Steels in Gaseous Hydrogen

Gaseous hydrogen is an alternative to petroleum-based fuels, but it is known to significantly reduce the fatigue and fracture resistance of steels. Steels are commonly used for containment and distribution of gaseous hydrogen, albeit under conservative operating conditions (i.e., large safety factors) to mitigate so-called gaseous hydrogen embrittlement. Economical methods of distributing gaseous hydrogen (such as using existing pipeline infrastructure) are necessary to make hydrogen fuel competitive with alternatives. The effects of gaseous hydrogen on fracture resistance and fatigue resistance of pipeline steels, however, has not been comprehensively evaluated and this data is necessary for structural integrity assessment in gaseous hydrogen environments. In addition, existing standardized test methods for environment assisted cracking under sustained load appear to be inadequate to characterize low-strength steels (such as pipeline steels) exposed to relevant gaseous hydrogen environments. In this study, the principles of fracture mechanics are used to compare the fracture and fatigue performance of two pipeline steels in high-purity gaseous hydrogen at two pressures: 5.5 MPa and 21 MPa. In particular, elastic-plastic fracture toughness and fatigue crack growth rates were measured using the compact tension geometry and a pressure vessel designed for testing materials while exposed to gaseous hydrogen.Copyright

Effect of High-Pressure Hydrogen Gas on Fracture of Austenitic Steels

Applications requiring the containment and transportation of hydrogen gas at pressures greater than 70 MPa are anticipated in the evolving hydrogen economy infrastructure. Since hydrogen is known to alter the mechanical properties of materials, data are needed to guide the selection of materials for structural components. The objective of this study is to characterize the role of yield strength, microstructural orientation, and small concentrations of ferrite on hydrogen-assisted fracture in two austenitic stainless steels: 21Cr-6Ni-9Mn (21-6-9) and 22Cr-13Ni-5Mn (22-13-5). The testing methodology involves exposure of tensile specimens to high-pressure hydrogen gas at elevated temperature in order to precharge the specimens with hydrogen, and subsequently testing the specimens in laboratory air to measure strength and ductility. In all cases, the alloys remain ductile despite precharging to hydrogen concentrations of ∼1 at. %, as demonstrated by reduction in area values between 30% and 60% and fracture modes dominated by microvoid processes. Low concentrations of ferrite and moderate increases in yield strength do not exacerbate hydrogen-assisted fracture in 21-6-9 and 22-13-5, respectively. Microstructural orientation has a pronounced effect on ductility in 22-13-5 due to the presence of aligned second-phase particles.

PRESSURE CYCLING OF STEEL PRESSURE VESSELS WITH GASEOUS HYDROGEN.

Steel pressure vessels are commonly used for the transport of pressurized gases, including gaseous hydrogen. In the majority of cases, these transport cylinders experience relatively few pressure cycles over their lifetime, perhaps as many as 25 per year, and generally significantly less. For fueling applications, as in fuel tanks on hydrogen-powered industrial trucks, the hydrogen fuel systems may experience thousands of cycles over their lifetime. Similarly, it can be anticipated that the use of tube trailers for large-scale distribution of gaseous hydrogen will require lifetimes of thousands of pressure cycles. This study investigates the fatigue life of steel pressure vessels that are similar to transport cylinders by subjecting full-scale vessels to pressure cycles with gaseous hydrogen between nominal pressure of 3 and 44 MPa. In addition to pressure cycling of vessels that are similar to those in service, engineered defects were machined on the inside of several pressure vessels to simulate manufacturing defects and to initiate failure after relatively low number of cycles. Failure was not observed in as-manufactured vessels with more than 55,000 pressure cycles, nor in vessels with relatively small, engineered defects subjected to more than 40,000 cycles. Large engineered defects (with depth greater than 5% of the wall thickness) resulted in failure after 8,000 to 15,000 pressure cycles. Defects machined to depths less than 5% wall thickness did not induce failures. Four pressure vessel failures were observed during the course of this project and, in all cases, failure occurred by leak before burst. The performance of the tested vessels is compared to two design approaches: fracture mechanics design approach and traditional fatigue analysis design approach. The results from this work have been used as the basis for the design rules for Type 1 fuel tanks in the standard entitled “Compressed Hydrogen-Powered Industrial Truck, On-board Fuel Storage and Handling Components (HPIT1)” from CSA America.Copyright

Fracture and fatigue tolerant steel pressure vessels for gaseous hydrogen.

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.Copyright

Fracture Resistance and Fatigue Crack Growth of X80 Pipeline Steel in Gaseous Hydrogen

Gaseous hydrogen is a convenient medium to store and transport energy. As existing petroleum-based platforms are electrified, such as with the growth of fuel cell systems, hydrogen is becoming an attractive fuel which must be distributed, stored and dispensed. Hydrogen is used extensively in refining of petroleum products, and often distributed by pipeline. However, there remains a need to quantify the mechanical properties of low-cost steels in gaseous hydrogen and to relate the measured performance to the variety of microstructures that characterize steels. This study is part of a larger effort to characterize a broad range of steels manufactured for pipelines and to measure their fracture and fatigue resistance in gaseous hydrogen. The fracture resistance and fatigue crack growth rates of two microstructural variations of X80 pipeline steel were measured in gaseous hydrogen at pressure of 21 MPa. The performance of these steels was found to be similar to the performance of other ferritic steels that are currently used to distribute gaseous hydrogen.Copyright

Measurement of Sustained-Load Cracking Thresholds for Steels in Hydrogen Delivery and Storage

Threshold stress intensity factors at crack arrest have been measured for three commercial low alloy pressure vessel steels, SA372 grade J, DOT 3AAX and DOT 3T as well as X100 line pipe steel using sustained load testing. Testing conditions were consistent with the recently published Article KD-10 from Section VIII, Division 3 of the ASME Boiler and Pressure Vessel Code. Measured threshold values for these steels suggest a higher resistance to hydrogen-assisted fracture than previously expected, however some improvements to the methodology of Article KD-10 may be required to ensure conservative results are measured. Specifically, conservative measurements of threshold stress intensity factor for hydrogen-assisted fracture cannot be determined without crack propagation.Copyright

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

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.Copyright

Fatigue Life of Austenitic Stainless Steel in Hydrogen Environments

Gas-handling components for high-pressure gaseous hydrogen (such as in the fuel system of fuel cell electric vehicles) are manufactured almost exclusively from austenitic stainless steels. Relatively few studies, however, have evaluated the fatigue life of this class of steels in hydrogen environments, especially at low temperature. Low temperature is important for two reasons: (1) austenitic stainless steels show an apparent minimum in tensile ductility at temperature near 220K when exposed to hydrogen environments; and (2) the service temperature range for the automotive industry is generally consider to be 233K to 358K (−40°C to +85°C). While the temperature of maximum hydrogen embrittlement from tensile tests is very near the minimum of the service temperature range, it remains unclear if the same trend applies to fatigue life properties. In this paper, we evaluate the effect of hydrogen on fatigue life of strain-hardened Type 316L. The tested alloy features a relatively high nickel content of 12 wt% and high yield strength of 590 MPa. Additionally, reduction of cost and weight of hydrogen-handling components is necessary to enhance the competitiveness of fuel cell vehicle technologies. Cost reductions can be achieved by considering alloys with lower nickel content, while higher strength materials enable lower weight. Simple estimates of cost and weight reductions that can be realized are discussed.Copyright

J-Integral modeling and validation for GTS reservoirs.

Non-destructive detection methods can reliably certify that gas transfer system (GTS) reservoirs do not have cracks larger than 5%-10% of the wall thickness. To determine the acceptability of a reservoir design, analysis must show that short cracks will not adversely affect the reservoir behavior. This is commonly done via calculation of the J-Integral, which represents the energetic driving force acting to propagate an existing crack in a continuous medium. J is then compared against a materials fracture toughness (J{sub c}) to determine whether crack propagation will occur. While the quantification of the J-Integral is well established for long cracks, its validity for short cracks is uncertain. This report presents the results from a Sandia National Laboratories project to evaluate a methodology for performing J-Integral evaluations in conjunction with its finite element analysis capabilities. Simulations were performed to verify the operation of a post-processing code (J3D) and to assess the accuracy of this code and our analysis tools against companion fracture experiments for 2- and 3-dimensional geometry specimens. Evaluation is done for specimens composed of 21-6-9 stainless steel, some of which were exposed to a hydrogen environment, for both long and short cracks.