Abstract
There is a global interest in decarbonizing the existing natural gas infrastructure by blending the natural gas with hydrogen. However, hydrogen is known to embrittle pipeline and pressure vessel steels used in gas transportation and storage applications. Thus, assessing the structural integrity of vintage pipeline (pre-1970s) in the presence of gaseous hydrogen is a critical step towards successful implementation of hydrogen blending into existing infrastructure. To this end, fatigue crack growth (FCG) behavior and fracture resistance of several vintage X52 pipeline steels were evaluated in high purity gaseous hydrogen environments at pressure of 210 bar (3,000 psi) and 34 bar (500 psi). The base metal and seam weld microstructures were characterized using optical microscopy, scanning electron microscopy (SEM) and Vickers hardness mapping. The base metals consisted of ferrite-pearlite banded microstructures, whereas the weld regions contained ferrite and martensite. In one case, a hook-like crack was observed in an electric resistance (seam) weld; whereas hard spots were observed near the bond line of a double-submerged arc (seam) weld. For a given hydrogen gas pressure, comparable FCG rates were observed for the different base metal and weld microstructures. Generally, the higher strength microstructures had lower fracture resistance in hydrogen. In particular, lower fracture resistance was measured when local hard spots were observed in the approximate region of the crack plane of the weld. Samples tested in lower H2 pressure (34 bar) exhibited lower FCG rates (in the lower ΔK regime) and greater fracture resistance when compared to the respective high-pressure (210 bar) hydrogen tests. The hydrogen-assisted fatigue and fracture surfaces were qualitatively characterized using SEM to rationalize the influence of microstructure on the dominant fracture mechanisms in gaseous hydrogen environment.
