This work discusses the design and demonstration of an in-situ test setup for testing pipeline steels in a high pressure gaseous hydrogen (H2) environment. A miniature hollow pipe-like tensile specimen was designed that acts as the gas containment volume during the test. Specific areas of the specimen can be forced to fracture by selective notching, as performed on the weldment. The volume of H2 used was minimised so the test can be performed safely without the need of specialised equipment. The setup is shown to be capable of characterising Hydrogen Embrittlement (HE) in steels through testing an X60 pipeline steel and its weldment. The percentage elongation (%El) of the base metal was found to be reduced by 40% when tested in 100 barg H2. Reduction of cross-sectional area (%RA) was found to decrease by 28% and 11% in the base metal and weld metal, respectively, when tested in 100 barg H2. Benchmark test were performed at 100 barg N2 pressure. SEM fractography further indicated a shift from normal ductile fracture mechanisms to a brittle transgranular (TG) quasi-cleavage (QC) type fracture that is characteristic of HE.

With fossil fuels being phased out and growing global interest in a hydrogen economy, there is demand for re-purposing existing pipelines for transportation of hydrogen gas. However, hydrogen embrittlement (HE) can limit pipeline steel's performance. In this study, the effect of hydrogen on the mechanical properties of an X60 base metal (polygonal ferrite/pearlite) and its girth weld (acicular ferrite/pearlite) was measured with a novel slow strain rate tensile (SSRT) test in which hollow pipe-like specimens were internally pressurised with nitrogen and hydrogen gas from 0 to 100 bars. Results showed that exposure to H 2 gas at 100 bars reduced the ductility of the base metal by up to 40% and the weld metal by 14%. Reduction in cross-sectional area (%RA) reduced by up to 28% in the base metal and 11% in the weld metal. Fracture surface analysis showed micro-void coalescence as well as quasi-cleavage fracture characteristic of HE. Susceptibility to HE was also observed in the form of secondary longitudinal and internal transverse cracks.

In this work, the hydrogen fatigue of pipeline steel X60, its girth welds and weld defects were investigated through in situ fatigue testing. A novel in situ gaseous hydrogen charging fatigue set-up was developed, which involves a sample geometry that mimics a small-scale pipeline with high internal hydrogen gas pressure. The effect of hydrogen was investigated by measuring the crack initiation and growth, using a direct current potential drop (DCPD) set-up, which probes the outer surface of the specimen. The base and weld metal specimens both experienced a reduction in fatigue life in the presence of hydrogen. For the base metal, the reduction in fatigue life manifested solely in the crack growth phase; hydrogen accelerated the crack growth by a factor of 4. The crack growth rate for the weld metal accelerated by a factor of 8. However, in contrast to the base metal, the weld metal also experienced a reduction of 57% in resistance to crack initiation. Macropores (>500 µm in size) on the notch surface reduced the fatigue life by a factor of 11. Varying the pressure from 70 barg to 150 barg of hydrogen caused no difference in the hydrogen fatigue behavior of the weld metal. The fracture path of the base and weld metal transitioned from transgranular and ductile in nature to a mixed-mode transgranular and intergranular quasi-cleavage fracture. Hydrogen accelerated the crack growth by decreasing the roughness- and plasticity-induced crack closure. The worst case scenario for pipelines was found in the case of weld defects. This work therefore highlights the necessity to re-evaluate pipelines for existing defects before they can be reused for hydrogen transport.