Publications

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Carbon-manganese steels are candidates for the structural materials in hydrogen gas pipelines; however, it is well known that these steels are susceptible to hydrogen embrittlement. Decades of research and industrial experience have established that hydrogen embrittlement compromises the structural integrity of steel components. This experience has also helped identify the failure modes that can operate in hydrogen containment structures. As a result, there are tangible ideas for managing hydrogen embrittlement in steels and quantifying safety margins for steel hydrogen containment structures. For example, fatigue crack growth aided by hydrogen embrittlement is a well-established failure mode for steel hydrogen containment structures subjected to pressure cycling. This pressure cycling represents one of the key differences in operating conditions between current hydrogen pipelines and those anticipated in a hydrogen delivery infrastructure. Applying structural integrity models in design codes coupled with measurement of relevant material properties allows quantification of the reliability/integrity of steel hydrogen pipelines subjected to pressure cycling. Furthermore, application of these structural integrity models is aided by the development of physics-based predictive models, which provide important insights such as the effects of microstructure on hydrogen-assisted fatigue crack growth. Successful implementation of these structural integrity and physics-based models enhances confidence in the design codes and enables decisions about materials selection and operating conditions for reliable and efficient steel hydrogen pipelines.

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The US Department of Energy (DOE) Energy Efficiency and Renewable Energy (EERE) Office of Fuel Cell Technologies Office (FCTO) is establishing the Hydrogen Fueling Infrastructure Research and Station Technology (H2FIRST) partnership, led by the National Renewable Energy Laboratory (NREL) and Sandia National Laboratories (SNL). FCTO is establishing this partnership and the associated capabilities in support of H2USA, the public/private partnership launched in 2013. The H2FIRST partnership provides the research and technology acceleration support to enable the widespread deployment of hydrogen infrastructure for the robust fueling of light-duty fuel cell electric vehicles (FCEV). H2FIRST will focus on improving private-sector economics, safety, availability and reliability, and consumer confidence for hydrogen fueling. This whitepaper outlines the goals, scope, activities associated with the H2FIRST partnership.

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Effects of low temperature on hydrogen-assisted cracking in 304L/308L austenitic stainless steel welds were investigated using elastic-plastic fracture mechanics methods. Thermally precharged hydrogen (140. wppm) decreased fracture toughness and altered fracture mechanisms at 293 and 223. K relative to hydrogen-free welds. At 293. K, hydrogen increased planar deformation in austenite, and microcracking of δ-ferrite governed crack paths. At 223. K, low temperature enabled hydrogen to exacerbate localized deformation, and microvoid formation, at austenite deformation band intersections near phase boundaries, dominated damage initiation; microcracking of ferrite did not contribute to crack growth. © 2013 Elsevier Ltd.

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Austenitic stainless steels have been extensively tested in hydrogen environments. These studies have identified the relative effects of numerous materials and environmental variables on hydrogen-assisted fracture. While there is concern that welds are more sensitive to environmental effects than the non-welded base material, in general, there have been relatively few studies of the effects of gaseous hydrogen on the fracture and fatigue resistance of welded microstructures. The majority of published studies have considered welds with geometries significantly different from the welds produced in assembling pressure manifolds. In this study, conventional, uniaxial tensile testing was used to characterize tubing of type 316L austenitic stainless steel with an outside diameter of 6.35 mm. Additionally, orbital tube welds were produced and tested to compare to the non-welded tubing. The effects of internal hydrogen were studied after saturating the tubes and orbital welds with hydrogen by exposure to high-pressure gaseous hydrogen at elevated temperature. The effects of hydrogen on the ductility of the tubing and the orbital tube welds were found to be similar to the effects observed in previous studies of type 316L austenitic stainless steels. Copyright © 2013 by ASME.

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 © 2013 by ASME.

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