L51621 Hydrogen-Related Failures at Mechanically Damaged Regions

Leaks attributed to hydrogen-stress cracking (HSC) initiating in regions of mild mechanical damage have been reported in cathodically protected pipe lines constructed from high-strength, microalloyed, controlled-rolled steels. The hydrogen is believed to be present in service from the cathodic potential applied. Laboratory studies were initiated to determine the factors that contributed to those unexpected failures. Strain aging at ambient temperatures as a result of deformation introduced during the mechanical damage, was found to be a significant factor. Smooth-bar specimens that were strained and then aged failed by HSC within one week, whereas specimens that were not strain aged did not fail by HSC. Result: The findings of this research indicate a potential sequence of events which may lead to hydrogen-related failures in regions of mild mechanical damage: (1) Following the damage, ambient-temperature strain aging which promotes sensitivity to HSC takes place in the mechanically damaged region, in a surface layer of the pipe wall which has been subjected to a critical level of strain. The time period for this step would be on the order of several years. (2) Electrochemical conditions which promote hydrogen charging develop at the pipe surface from the cathodic current applied (or possibly corrosion). (3) Local stresses in the mechanically damaged region are elevated above the threshold stress for HSC by the moderate stress concentration provided by the mechanical damage. For the X70 pipe studied, the stress elevation should be at least 20 percent above the nominal hoop stress. (4) An HSC crack initiates and grows in the strain-aged surface layer. (5) The crack propagates further by HSC, through the non-strain-aged portion of the wall, as a result of the high stress concentration at the crack tip. (6) When the crack grows to a critical depth, it propagates rapidly through the wall by overload and causes a leak.