Stress-Corrosion-Cracking Sensitivity of the Sub-Zones in X80 Steel Welded Joints at Different Potentials.

X80 steel plays a pivotal role in the development of oil and gas pipelines; however, its welded joints, particularly the heat-affected zone (HAZ), are susceptible to stress corrosion cracking (SCC) due to their complex microstructures. This study investigates the SCC initiation mechanisms of X80 steel welded joints under practical pipeline conditions with varying levels of cathodic protection. The SCC behaviors were analyzed through electrochemical measurements, hydrogen permeation tests, and interrupted slow strain rate tensile tests (SSRTs) conducted in a near-neutral pH environment under different potential conditions (OCP, -1.1 VSCE, -1.2 VSCE). These behaviors were influenced by microstructure type, grain size, martensite/austenite (M/A) constituents, and dislocation density. The sub-zones of the weld exhibited differing SCC resistance, with the fine-grain (FG) HAZ, base metal (zone), welded metal (WM) zone, and coarse-grain (CG) HAZ in descending order. In particular, the presence of coarse grains, low dislocation density, and extensive M/A islands collectively increased corrosion susceptibility and SCC sensitivity in the CGHAZ compared to other sub-zones. The SCC initiation mechanisms of the sub-zones within the X80-steel welded joint were primarily anodic dissolution (AD) under open-circuit potential (OCP) condition, shifting to either hydrogen-enhanced local plasticity (HELP) or hydrogen embrittlement (HE) mechanisms at -1.1 VSCE or -1.2 VSCE, respectively.

The Effects of Hot Isostatic Pressing (HIP) and Heat Treatment on the Microstructure and Mechanical Behavior of Electron Beam-Melted (EBM) Ti-6Al-4V Alloy and Its Susceptibility to Hydrogen.

The effects of the secondary processes of Hot Isostatic Pressing (HIP) at 920 °C and Heat Treatment (HT) at 1000 °C of Electron Beam-Melted (EBM) Ti-6Al-4V alloy on the microstructure and hydrogen embrittlement (HE) after electrochemical hydrogen charging (EC) were investigated. Comprehensive characterization, including microstructural analysis, X-ray diffraction (XRD), thermal desorption analysis, and mechanical testing, was conducted. After HIP, the ß-phase morphology changed from discontinuous Widmanstätten to a more continuous structure, 10 times and ~1.5 times larger in length and width, respectively. Following HT, the ß-phase morphology changed to a continuous "web-like" structure, ~4.5 times larger in width. Despite similar mechanical behavior in their non-hydrogenated state, the post-treated alloys exhibit increased susceptibility to HE due to enhanced hydrogen penetration into the bulk. It is shown that hydrogen content in the samples' bulk is inversely dependent on surface hydride content. It is therefore concluded that the formed hydride surface layer is crucial for inhibiting further hydrogen penetration and adsorption into the bulk and thus for reducing HE susceptibility. The lack of a hydride surface layer in the samples subject to HIP and HT highlights the importance of choosing secondary treatment process parameters that will not increase the continuous ß-phase morphology of EBM Ti-6Al-4V alloys in applications that involve electrochemical hydrogen environments.

Oxidation Driven Damage on SiC/BN/SiC Ceramic Matrix Composite Aero-Engine Structures: An Iterative Computational Framework.

Ceramic matrix composites (CMCs) could be a game changer in the aero-engine industry. Their density is circa one-third of their metallic counterpart. CMCs, furthermore, offer increased strength and greater capability at very high temperatures. This would allow for a reduction in cooling and an increased engine performance. Some challenges, besides the complexity of the manufacturing process, however, remain for the structural integrity of this technology. CMCs are inherently brittle; furthermore, they tend to oxidise when attacked by water or oxygen, and their constituents become brittle and more prone to failure. There are two main points of novelty proposed by this work. The first one is to model and reproduce recent oxidation experimental data with a simple Fick's law implemented in Abaqus. The parameters of this modelling are a powerful tool for the design of such material systems. The second aspect consists in the development of a new computational framework for iteratively calculating oxygen diffusion and stiffness degradation of the material. Oxidation and stiffness degradation are in fact coupled phenomena. The crack (or microcracking) opening, the function of applied stress, accelerates oxygen diffusion whilst the oxidation diffusion itself contributes to embrittlement and then damage introduction in the material system.

Impact of Size and Distribution of k-Carbides on the Hydrogen Embrittlement and Trapping Behaviors of a Fe-Mn-Al-C Low-Density Steel.

This study compares the hydrogen embrittlement susceptibility of a Fe-30Mn-8Al-1.2C austenitic low-density steel aged at 600 °C for 0 (RX), 1 min (A1) and 60 min (A60), each exhibiting varying sizes and distributions of nano-sized κ-carbides. Slow strain rate tests were conducted to assess hydrogen embrittlement susceptibility, while thermal desorption analysis was applied to investigate hydrogen trapping behaviors. Fracture surface analysis was employed to discuss the associated failure mechanisms. The results suggest that nano-sized κ-carbides with sizes ranging from 2-4 nm play a crucial role in mitigating hydrogen embrittlement, contrasting with the exacerbating effect of coarse grain boundary κ-carbides. This highlights the significance of controlling the sizes and morphology of precipitates in designing hydrogen-resistant materials.

Change in Hydrogen Trapping Characteristics and Influence on Hydrogen Embrittlement Sensitivity in a Medium-Carbon, High-Strength Steel: The Effects of Heat Treatments.

Medium-carbon, high-strength steels are widely used in the field of hydrogen energy because of their good mechanical properties, and they can be readily tailored by heat treatment processes such as the normalizing-tempering (N&T) and quenching-tempering (Q&T) methods. The hydrogen embrittlement (HE) susceptibility of a medium-carbon, high-strength steel was investigated utilizing microstructural characterization with scanning electron microscopy (SEM), the electron backscatter diffraction (EBSD) technique, and transmission electron microscopy (TEM). A study was also conducted on the steel's hydrogen transport behavior as affected by the N&T and Q&T treatments. The steel contained more hydrogen traps, such as dislocations, grain boundaries, lath boundaries, and carbide interfaces, after the Q&T process, which was associated with a lower HE sensitivity when comparing the two treatments. In comparison, the N&T process produced larger-size and lesser-density carbides distributed along the grain boundaries, and this resulted in a relatively higher HE susceptibility, as revealed by the slow-strain-rate tensile (SSRT) tests of the hydrogen-charged steels and by the fractographic study of the fracture surface.

Hydrogen Embrittlement of 27Cr-4Mo-2Ni Super Ferritic Stainless Steel.

The effect of hydrogen content on the deformation and fracture behavior of 27Cr-4Mo-2Ni super ferritic stainless steel (SFSS) was investigated in this study. It was shown that the plasticity and yield strength of SFSS were very susceptible to hydrogen content. The introduction of hydrogen led to a significant decrease in elongation and a concurrent increase in yield strength. Nevertheless, a critical threshold was identified in the elongation reduction, after which the elongation remained approximately constant even with more hydrogen introduced, while the yield strength exhibited a monotonic increase with increasing hydrogen content within the experimental range, attributed to the pinning effect of the hydrogen Cottrell atmosphere on dislocations. Furthermore, the hydrogen-charged SFSS shows an apparent drop in flow stress after upper yielding and a reduced work hardening rate during the subsequent plastic deformation. The more hydrogen is charged, the more the flow stress drops, and the lower the work hardening rate becomes.

Experimental Study on Liquid Metal Embrittlement of Al-Zn-Mg Aluminum Alloy (7075): From Macromechanical Property Experiment to Microscopic Characterization.

This study is a multiscale experimental investigation into the embrittlement of Al-Zn-Mg aluminum alloy (7075-T6) caused by liquid metal gallium. The results of the experiment demonstrate that the tensile strength of the 7075-T6 aluminum alloy significantly weakens with an increase in the embrittlement temperature and a prolonged embrittlement time, whereas it improves with an increase in the strain rate. On the basis of the analysis of the experimental data, the sensitivity of the embrittlement of 7075-T6 aluminum alloy by liquid gallium to the loading strain rate is significantly higher compared to other environmental factors. In addition, this study also includes several experiments for microscopic observation, such as Scanning Electron Microscope (SEM) observation, Energy-Dispersive Spectrometer (EDS) spectroscopy, and Electron Back Scatter Diffraction (EBSD) analysis. The experimental observations confirmed the following: (1) gallium is enriched in the intergranular space of aluminum; (2) the fracture mode of 7075-T6 aluminum alloy changes from ductile to brittle fracture; and (3) the infiltration of liquid gallium into aluminum alloys and its enrichment in the intergranular space result in the formation of new dislocation nucleation sites, in addition to the original dislocations cutting and entanglement. This reduces the material's ability to undergo plastic deformation, intensifies stress concentration at the dislocation nucleation point, and, ultimately, leads to the evolution of dislocations into cracks.

Evaluation of the Embrittlement in Reactor Pressure-Vessel Steels Using a Hybrid Nondestructive Electromagnetic Testing and Evaluation Approach.

The nondestructive determination of the neutron-irradiation-induced embrittlement of nuclear reactor pressure-vessel steel is a very important and recent problem. Within the scope of the so-called NOMAD project funded by the Euratom research and training program, novel nondestructive electromagnetic testing and evaluation (NDE) methods were applied to the inspection of irradiated reactor pressure-vessel steel. In this review, the most important results of this project are summarized. Different methods were used and compared with each other. The measurement results were compared with the destructively determined ductile-to-brittle transition temperature (DBTT) values. Three magnetic methods, 3MA (micromagnetic, multiparameter, microstructure and stress analysis), MAT (magnetic adaptive testing), and Barkhausen noise technique (MBN), were found to be the most promising techniques. The results of these methods were in good agreement with each other. A good correlation was found between the magnetic parameters and the DBTT values. The basic idea of the NOMAD project is to use a multi-method/multi-parameter approach and to focus on the synergies that allow us to recognize the side effects, therefore suppressing them at the same time. Different types of machine-learning (ML) algorithms were tested in a competitive manner, and their performances were evaluated. The important outcome of the ML technique is that not only one but several different ML techniques could reach the required precision and reliability, i.e., keeping the DBTT prediction error lower than a ±25 °C threshold, which was previously not possible for any of the NDE methods as single entities. A calibration/training procedure was carried out on the merged outcome of the testing methods with excellent results to predict the transition temperature, yield strength, and mechanical hardness for all investigated materials. Our results, achieved within the NOMAD project, can be useful for the future potential introduction of this (and, in general, any) nondestructive evolution method.

Effect of Strain Rate on Hydrogen Embrittlement of Ti6Al4V Alloy.

The phenomenon of hydrogen embrittlement (HE) in metals and alloys, which determines the performance of components in hydrogen environments, has recently been drawing considerable attention. This study explores the interplay between strain rates and solute hydrogen in inducing HE of Ti6Al4V alloy. For the hydrogen-charged sample, as the strain rate was decreased from 10-2/s to 10-5/s, the ductility decreased significantly, but the HE effect on mechanical strength was negligible. The low strain rate (LSR) conditions facilitated the development of high-angle grain boundaries, providing more pathways for hydrogen diffusion and accumulation. The presence of solute hydrogen intensified the formation of nano/micro-voids and intergranular cracking tendencies, with micro-crack occurrences observed exclusively in the LSR conditions. These factors expanded the brittle hydrogen-damaged region more deeply into the interior of the lattice. This, in turn, accelerated both crack initiation and intergranular crack propagation, finally resulting in a considerable HE effect and a reduction in ductility at the LSR. The current study underscores the influence of strain rate on HE, enhancing the predictability of longevity and improving the reliability of components operating in hydrogen-rich environments under various loading conditions.

Influence of Calcareous Deposits on Hydrogen Embrittlement Susceptibility of Q460 Steel.

Cathodic protection is widely used to protect structural steel from corrosion in marine environments. However, an inappropriate cathodic potential may lead to hydrogen embrittlement (HE). Therefore, this study investigates the relationship between cathodic protection potential, structure and composition of calcareous deposits, and hydrogen embrittlement susceptibility of Q460 steel. The slow strain rate test results and fracture analysis reveal that Q460 steel had the smallest HE susceptibility when covered with the calcareous deposits formed under -1.1 VSCE. The deposits have a relatively thin calcium-rich inner layer and a condensed magnesium-rich outer layer, which can significantly inhibit hydrogen entry. A sustained deposition reaction during slow strain rate testing (SSRT) in artificial seawater can also decrease the HE susceptibility of Q460 steel.

Deciphering Hydrogen Embrittlement Mechanisms in Ti6Al4V Alloy: Role of Solute Hydrogen and Hydride Phase.

Ti6Al4V (Ti64) is a versatile material, finding applications in a wide range of industries due to its unique properties. However, hydrogen embrittlement (HE) poses a challenge in hydrogen-rich environments, leading to a notable reduction in strength and ductility. This study investigates the complex interplay of solute hydrogen (SH) and hydride phase (HP) formation in Ti64 by employing two different current densities during the charging process. Nanoindentation measurements reveal distinct micro-mechanical behavior in base metal, SH, and HP, providing crucial insights into HE mechanisms affecting macro-mechanical behavior. The fractography and microstructural analysis elucidate the role of SH and HP in hydrogen-assisted cracking behaviors. The presence of SH heightens intergranular cracking tendencies. In contrast, the increased volume of HP provides sites for crack initiation and propagation, resulting in a two-layer brittle fracture pattern. The current study contributes to a comprehensive understanding of HE in Ti6Al4V, essential for developing hydrogen-resistant materials.

Hydrogen Impact: A Review on Diffusibility, Embrittlement Mechanisms, and Characterization.

Hydrogen embrittlement (HE) is a broadly recognized phenomenon in metallic materials. If not well understood and managed, HE may lead to catastrophic environmental failures in vessels containing hydrogen, such as pipelines and storage tanks. HE can affect the mechanical properties of materials such as ductility, toughness, and strength, mainly through the interaction between metal defects and hydrogen. Various phenomena such as hydrogen adsorption, hydrogen diffusion, and hydrogen interactions with intrinsic trapping sites like dislocations, voids, grain boundaries, and oxide/matrix interfaces are involved in this process. It is important to understand HE mechanisms to develop effective hydrogen resistant strategies. Tensile, double cantilever beam, bent beam, and fatigue tests are among the most common techniques employed to study HE. This article reviews hydrogen diffusion behavior, mechanisms, and characterization techniques.

Hydrogen-triggered metal filament rupture in Cu-based resistance switches.

Cation-based resistance switches have been considered as promising candidates for memory cells and other novel devices. So far, the most accepted switching processes of such devices are based on the formation/rupture of metallic filaments between two electrodes. Although many recent studies have identified the existence of H2O (and resulting -OH groups) in such devices, their effects on the switching process are still unclear. In the present work, by taking Cu/Ta2O5/Pt device as an example, we have theoretically revealed that H ions may dissociate from -OH groups and accumulate onto the Cu filament in amorphous Ta2O5. After that, the adsorbed H ions will induce a series of changes, such as the elongation of the adjacent Cu-Cu bonds, the weakening of the Cu-Cu bonds, the increase of charge on Cu cations, and the enhancement of diffusivities of Cu cations, all of which eventually lead to the rupture of the Cu filament. Interestingly, our proposed 'H-triggered metal filament rupture' model is similar to the widely studied 'hydrogen embrittlement phenomenon'. The crucial point of this model is the high catalytic activity of Cu towards the splitting of -OH group. Consequently, it is expected that this model could be applicable to other Cu-cation based resistance switches.

Cation-based resistance switches have been considered as the promising candidates for memory cells and other novel devices. So far, the most accepted switching processes of such devices are based on the forming/rupture of metallic filaments between two electrodes. Although many recent studies have identified the existence of H₂O (and as-resulted -OH groups) in such devices, their effects on the switching process are still unclear. In the present work, by taking Cu/Ta₂O₅/Pt device as an example, we have theoretically proposed that the H ions take the very important role during the rupture process of Cu filament in such device. Interestingly, our proposed 'H-triggered metal filament rupture' model is similar to the widely studied 'Hydrogen Embrittlement' phenomenon in the industry field, which serves as additional evidence supporting the credibility of such model. The crucial point of mechanism of this model is considered to be the high catalytic activity of Cu towards the splitting of -OH group. Consequently, it is expected that this model could be applicable to other Cu-cation based resistance switches.

Embrittlement Mechanisms of HR3C Pipe Steel at Room Temperature in Ultra-Supercritical Unit.

HR3C steel is an austenitic high-temperature-resistant steel. Because of its good strength and high-temperature performance, it has been widely used in ultra-supercritical power plant boilers. With the increasingly frequent start-up and shutdown of thermal power units, leakages of HR3C steel pipes have occasionally occurred due to the embrittlement of HR3C pipe steel after a long service duration. In this study, the embrittlement mechanisms of HR3C pipe steel are investigated systematically. The mechanical properties of the pipe steel after running for 70,000 h in an ultra-supercritical unit were determined. As a comparison, the pipe steel supplied in the same batch was aged at 700 degrees Celsius for 500 h. The mechanical properties and the micro-precipitation of the aged counterparts were also determined for comparison. The results show that the embrittlement of HR3C pipe steel in service for 70,000 h is obvious. The average impact absorption is only 5.5 J, which is a decrease of 96.7%. It is found that embrittlement of HR3C steel also occurs after 500 h of aging at 700 °C, and the average value of impact absorption energy decreases by 70.4%. The comparison experiment between the in-service pipe steel and the aged pipe steel shows that in the rapid decline stage of the impact toughness of HR3C steel, the M23C6 carbide in the microstructure has a continuous chain distribution in the grain boundary. There were no other precipitated phases observed. The rapid precipitation and aggregation of M23C6 carbides leads to the initial embrittlement of HR3C steel at room temperature. The CRFe-type σ phase was found in the transmission electron microscope (TEM) image of the steel pipe after 70 thousand hours of use. The precipitation of the σ phase further induces the embrittlement of HR3C pipe steel after a long service duration.

Embrittlement Fracture Behavior and Mechanical Properties in Heat-Affected Zone of Welded Maraging Steel.

In welded maraging steels, mechanical properties, particularly ductility and toughness, are often compromised in the heat-affected zone (HAZ). This study focuses on 300-grade maraging steel bars, solution annealed at 1123 K for 1.5 h (5.4 ks) and welded using gas tungsten arc welding, followed by a post-weld heat treatment at 753 K for 13.33 h (48 ks). In situ observations during three-point bending tests on HAZ samples featuring coarsened prior austenite grain sizes were conducted to examine damage behavior and the crack path near the crack tip. The main crack initiated at the peak applied load during the bending test and, upon further loading, exhibited significant deflection and extension accompanied by numerous microcracks and localized crack branching. Distinctive damage features, such as transgranular cracking across block regions, intense intergranular cracking along packet boundaries with a pronounced shear component, and crowding of microcracks ahead of the crack tip, were observed in the HAZ sample during the in situ test. The interaction between the main crack tip and microcracks and its influence on the local crack propagation driving force was discussed using fracture mechanics. Experimental results, including tensile fracture surface observations and in situ images, along with analysis of the stress anti-shielding effect by microcracks, suggest that the HAZ sample exhibits embrittlement fracture behavior with lower ductility and toughness compared to the base metal sample.

Copper Alloy Design for Preventing Sulfur-Induced Embrittlement in Copper.

This study presents an experimental approach to address sulfur-induced embrittlement in copper alloys. Building on recent theoretical insights, we identified specific solute elements, such as silicon and silver, known for their strong binding affinity with vacancies. Through experimental validation, we demonstrated the effectiveness of Si and Ag in preventing sulfur-induced embrittlement in copper, even though they are not typical sulfide formers such as zirconium. Additionally, our findings highlight the advantages of these elements over traditional solutes, such as their high solubility and propensity to accumulate along grain boundaries. This approach may have the potential to be applied to other metals prone to sulfur-induced embrittlement, including nickel, iron, and cobalt, offering broader implications for materials engineering strategies and alloy development.

In situ TEM studies on hydrogen-related issues: hydrogen storage, hydrogen embrittlement, fuel cells and electrolysis.

Hydrogen is attracting attention as an energy carrier for realizing a low-carbon society, because it can directly convert the energy obtained from chemical reactions into electrical energy without carbon dioxide emissions. This paper presents in situ transmission electron microscopy (TEM) observations related to hydrogen storage in metal and metal hydrides, hydrogen embrittlement of metallic materials used for storing and transporting hydrogen in containers and pipes, and fuel cells and water electrolysis using metal catalysts and oxides as electrode materials. All of these processes are important for practical applications of hydrogen. Numerous in situ TEM studies have revealed the microscopic structural changes when hydrogen reacts with the materials, when hydrogen is solidly dissolved in the materials and during the operation of the material. This review is expected to facilitate further development of TEM operando observations of hydrogen-related materials.

A new research proposal to prevent hydrogen embrittlement for nuclear waste container by bacteria-a mini review.

A large amount of nuclear waste produced in the process of nuclear energy utilization has always been a key problem to be solved urgently for nuclear safety. At present, "deep geological disposal" is a feasible method and generally accepted by many countries. The oxygen content in the near field environment of the waste container will decrease to anaerobic conditions, and hydrogen will permeation into the internal materials of container for a long time. Hydrogen evolution corrosion may cause a risk of hydrogen embrittlement. The harm of hydrogen embrittlement in metal container is far more severe than predictable uniform corrosion. It is a research hotspot that the microorganisms impact on the corrosion behavior of container materials in the deep geological environment. Microbial corrosion in deep geological environments can be divided into two types: aerobic microbial corrosion and anaerobic microbial corrosion. There is a type of hydrogen consuming microorganism in the natural environment that uses the oxidation of hydrogen as the energy for its life activities. This provides a new approach for us to study reducing the hydrogen embrittlement sensitivity of nuclear waste container materials.

Influence of the Change of Phase Composition of (1 - x)ZrO2-xAl2O3 Ceramics on the Resistance to Hydrogen Embrittlement.

The article describes the influence of the change in the phase composition of ceramics on the stability of the crystal structure and retention of thermo-physical parameters during hydrogenation of the surface layer in the proton irradiation process. The selection of irradiation conditions allows modeling the degradation processes of ceramics associated with gas swelling during hydrogenation, as well as revealing the patterns of the effect of phase composition on embrittlement, de-strengthening, and structural degradation resistance. In the course of the conducted studies, dose-dependencies of irradiation-induced structural changes and consecutive accumulation of radiation-induced damage in ceramics as a result of hydrogenation of the damaged near-surface layer were established. It was found that the maximum structural changes are observed at doses above 1015 protons/cm2. Dependencies of the change in the degree of structural order as a function of the dose of accumulated damage and the concentration of accumulated protons were obtained. It was established that the variation of the ceramics phase composition due to the formation of solid solutions of ZrO2/Al2O3 and ZrO2/Al2O3/AlZr3 type leads to an enhancement of resistance to swelling by 3-5 times in comparison with monoclinic ZrO2 ceramics. The general analysis of the variation of strength and thermo-physical parameters of ceramics as a function of irradiation fluence for ceramics with different phase compositions showed a direct dependence of the decrease in hardness, resistance to cracking, and thermal conductivity on the concentration of deformation structural distortions caused by irradiation.

Metallographic Evaluation of Increased Susceptibility to Intermediate Embrittlement of Engine Valve Forgings Made of NCF 3015 High Nickel and Chromium Steel.

This paper focused on determining the increased tendency of cracking after the die forging process of high nickel and chromium steel. The increase in carbon content in austenitic nickel-chromium steel promoted the tendency of valve forgings to forging intergranular crack on the valve head. Attention was paid to issues related to the chemical composition of the material to be considered when hot forming nickel-chromium steel components. Optical and scanning electron microscopies were used to examine the microstructure and fracture features of the samples removed from a fractured valve head. The embrittlement was due to microcavity formation at grain boundaries. Creep theory at grain boundaries was used to explain crack formation. The tensile behavior was interpreted from the evolution of the microstructure during deformation and referred to intermediate brittleness to explain the effect of carbon. It was found that the increased carbon content of the nickel-chromium steel and the strong undercooling observed at the edges of the valve head are factors that promote a reduction in grain boundary cohesion and enhance intermediate temperature embrittlement. Finally, it was found that the formation of a heterogeneous structure manifested by the presence of grain boundary M23C6-type carbides in the austenitic matrix was most likely related to the occurring brittleness.