Mechanism of failure by hydrogen-induced cracking in pipeline steels

Pipeline steels that carry oil and natural gas in severe environments suffer from two important modes of failure: stress corrosion cracking (SCC) and hydrogen-induced cracking (HIC). The SCC has been studied extensively in the literature; however, HIC phenomenon in pipeline steels is less investigated by researchers. Nevertheless, HIC is recognized as the most important damage mode in sour environment. Hydrogen atoms produced due to surface corrosion of the steel diffuse into it through microstructural defects. When a critical amount of hydrogen is accumulated in such defects, HIC cracks initiate and propagate. The main objectives of this thesis are to find the HIC crack nucleation and propagation sites, evaluate a role of texture and grain boundary character distribution in crack growth and finally establish the effect of different microstructural parameters contributing to the HIC related failure in pipeline steel. In this thesis, HIC standard test and electrochemical hydrogen-charging experiments were used to induce HIC cracks in pipeline steels. HIC cracks at the cross section of tested samples were observed using scanning electron microscope (SEM). The SEM observations clearly indicate that the investigated X60 and X70 steels are susceptible to HIC while the X60SS steel showed a higher resistance to HIC. This experiment also proved that the X70 steel has higher susceptibility to HIC than the other investigated steel. Energy dispersive spectroscopic (EDS) analyses indicated that two types of inclusion namely manganese sulfide and carbonitiride precipitates serve as crack nucleation sites. HIC cracks were observed to propagate at the center of cross section where the segregation of some elements such as carbon and manganese occurred. Moreover, two other experiments were carried out in order to evaluate the capability of pipeline steels for hydrogen-trapping. The first test, hydrogen-permeation experiment, showed that all pipeline steel specimens, such as X70, X60 and X60SS steels, contain both reversible and irreversible hydrogen traps. However, the density of traps at the center of cross section was higher than other regions in all tested specimens. The hydrogen-discharging experiments also showed that all specimens keep a considerable amount of hydrogen inside their traps. The hydrogen traps, based on their binding energy with the metal matrix, are categorized as reversible (weak) and irreversible (strong) traps and the roles of each type of traps are explained. Electron backscatter diffraction (EBSD) measurements were done along the HIC crack in X70 steel after standard HIC test. The results showed that the {100} texture was strong while the {111} texture was weak. Some special texture components, such as the {110}, {332} and {112}, were observed after the HIC crack-stoppage. EBSD results also documented that fine grain colonies were prone to intergranular HIC crack propagation and IPF and PF, calculated in both sides of HIC cracks, showed the preferences of ND|| orientation. Both susceptible X60 and non-susceptible X60SS steel to HIC were compared based on the EBSD results. It was observed that the high amount of recrystallization fraction with no stored energy is one of the main reasons for a higher HIC resistance of X60SS steel to HIC. Moreover, Kernel Average Misorientation (KAM) data showed that the deformation is more concentrated in the as-received and HIC tested X60 specimens. The effect of hydrogen-charging during tensile/fatigue loading of X60SS steel was studied and it was observed that some HIC cracks at the cross section of X60SS steel were appeared after hydrogen-charging at stresses below the yield stress. Experiments were carried out to understand the effect of cold-rolling and annealing on HIC susceptibility in pipeline steels. The results documented that the {100} dominant texture is more pronounced in 50% and 90% cold-rolled and annealed specimens. The effect of different factors such as KAM degree and recrystallized fraction affecting HIC susceptibility on cold-rolled and annealed specimens was investigated. The obtained results showed that the cold-rolling and annealing process may not be considered as an effective method to increase HIC resistance in pipeline steels

Improvement of tensile properties by controlling the microstructure and crystallographic data in commercial pearlitic carbon-silicon steel via quenching and partitioning (Q&P) process

In the current research, a complex microstructure and crystallographic data were developed through quenching and partitioning (Q&P) process to improve tensile properties of commercial pearlitic carbon-silicon steel. Two-stage Q&P process, including full austenitization, quenching at 220 °C, followed by two different partitioning temperatures, was applied to the as-received specimen to generate a complex microstructure composed of tempered martensite, bainite, ultrafine carbides/martensite-austenite/retained austenite particles. Microstructure and crystallographic data were investigated by scanning electron microscopy, electron backscattered diffraction (EBSD), and X-ray diffraction techniques. Then, hardness and tensile properties were evaluated to confirm the improvement of mechanical properties. Dilatation-temperature curves exhibited the kinetics of martensitic and bainitic transformation during quenching and isothermal partitioning stages. The presence of nano-carbide particles inside athermal martensite was confirmed by electron microscopy due to the pre-formed martensite carbon depletion during the partitioning stage coupled with bainitic transformation. The formation of preferential atomic-compact direction in BCC (martensite/bainite) plates characterized by EBSD, could enhance ductility by providing adequate slip systems. Point-to-point misorientation analyses demonstrated a slight dominance of low angle boundaries proportion in bainitic dominance structure in Q&P-220-375 specimen, which could be used in phase characterization. Results revealed that the development of nanoscale carbide dispersed in refined bainite/martensite matrix boosted the yield and ultimate tensile strength by over 100% and 110% compared to the initial pearlitic microstructure. However, ductility reduced to half value in Q&P-220-325 and Q&P-220-375 specimens.Peer ReviewedPostprint (published version

Effects of Different Parameters on Initiation and Propagation of Stress Corrosion Cracks in Pipeline Steels: A Review

The demand for pipeline steels has increased in the last several decades since they were able to provide an immune and economical way to carry oil and natural gas over long distances. There are two important damage modes in pipeline steels including stress corrosion cracking (SCC) and hydrogen induced cracking (HIC). The SCC cracks are those cracks which are induced due to the combined effects of a corrosive environment and sustained tensile stress. The present review article is an attempt to highlight important factors affecting the SCC in pipeline steels. Based on a literature survey, it is concluded that many factors, such as microstructure of steel, residual stresses, chemical composition of steel, applied load, alternating current (AC) current and texture, and grain boundary character affect the SCC crack initiation and propagation in pipeline steels. It is also found that crystallographic texture plays a key role in crack propagation. Grain boundaries associated with {111}∥rolling plane, {110}∥rolling plane, coincidence site lattice boundaries and low angle grain boundaries are recognized as crack resistant paths while grains with high angle grain boundaries provide easy path for the SCC intergranular crack propagation. Finally, the SCC resistance in pipeline steels is improved by modifying the microstructure of steel or controlling the texture and grain boundary character

Different aspects of hydrogen diffusion behavior in pipeline steel

In this paper, hydrogen diffusion behavior in pipeline steel is thoroughly investigated. The effect of various microstructural factors affecting hydrogen diffusion are discussed using literature review. The results of this survey show that the hydrogen diffusion in pipeline steels depends strongly on the microstructure of steel, crystallographic texture, dislocation density, grain size, presence of different elements, precipitates and inclusions. Based on the results, the interfaces between the retained austenite and martensitic layer are considered as the possible hydrogen trap sites. Moreover, the apparent diffusivity decrease due to hydrogen trapping by dislocations is well documented without need for cyclic loading. The grain size and nature of grain boundaries plays an important role in the hydrogen diffusion and trapping. There is an optimum grain size in which the hydrogen diffusion reaches its maximum value. Various elements, inclusions and precipitates which are present in the microstructure of pipeline steel have a considerable role in hydrogen diffusion. Based on the hydrogen microprint technique results, the increase in the grain size decreases the hydrogen trapping by triple junctions and grain boundaries

Thermal Shock Behavior of Twill Woven Carbon Fiber Reinforced Polymer Composites

In the current research, the effect of cyclic temperature variation on the mechanical and thermal properties of woven carbon-fiber-reinforced polymer (CFRP) composites was investigated. To this, carbon fiber textiles in twill 2/2 pattern were used as reinforced phase in epoxy, and CFRPs were fabricated by vacuum-assisted resin-infusion molding (VARIM) method. Thermal cycling process was carried out between −40 and +120 °C for 20, 40, 60 and 80 cycles, in order to evaluate the effect of thermal cycling on mechanical and thermal properties of CFRP specimens. In this regard, tensile, bending and short beam shear (SBS) experiments were carried out, to obtain modulus of elasticity, tensile strength, flexural modulus, flexural strength and inter-laminar shear strength (ILSS) at room temperature (RT), and then thermal treated composites were compared. A dynamic mechanical analysis (DMA) test was carried out to obtain thermal properties, and viscoelastic properties, such as storage modulus (E’), loss modulus (E”) and loss factors (tan δ), were evaluated. It was observed that the characteristics of composites were affected by thermal cycling due to post-curing at a high temperature. This process worked to crosslink and improve the composite behavior or degrade it due to the different coefficients of thermal expansion (CTEs) of composite components. The response of composites to the thermal cycling process was determined by the interaction of these phenomena. Based on SEM observations, the delamination, fiber pull-out and bundle breakage were the dominant fracture modes in tensile-tested specimens