Chapter 91 Hydrogen Effects on Plasticity

Hydrogen Embrittlement as a Conspicuous Material Challenge─Comprehensive Review and Future Directions

Hydrogen is considered a clean and efficient energy carrier crucial for shaping the net-zero future. Large-scale production, transportation, storage, and use of green hydrogen are expected to be undertaken in the coming decades. As the smallest element in the universe, however, hydrogen can adsorb on, diffuse into, and interact with many metallic materials, degrading their mechanical properties. This multifaceted phenomenon is generically categorized as hydrogen embrittlement (HE). HE is one of the most complex material problems that arises as an outcome of the intricate interplay across specific spatial and temporal scales between the mechanical driving force and the material resistance fingerprinted by the microstructures and subsequently weakened by the presence of hydrogen. Based on recent developments in the field as well as our collective understanding, this Review is devoted to treating HE as a whole and providing a constructive and systematic discussion on hydrogen entry, diffusion, trapping, hydrogen-microstructure interaction mechanisms, and consequences of HE in steels, nickel alloys, and aluminum alloys used for energy transport and storage. HE in emerging material systems, such as high entropy alloys and additively manufactured materials, is also discussed. Priority has been particularly given to these less understood aspects. Combining perspectives of materials chemistry, materials science, mechanics, and artificial intelligence, this Review aspires to present a comprehensive and impartial viewpoint on the existing knowledge and conclude with our forecasts of various paths forward meant to fuel the exploration of future research regarding hydrogen-induced material challenges.

Hydrogen-Induced Dislocation Nucleation and Plastic Deformation of 〈001〉 and 〈11¯0〉 Grain Boundaries in Nickel

The grain boundary (GB) plays a crucial role in dominating hydrogen-induced plastic deformation and intergranular failure in polycrystal metals. In the present study, molecular dynamics simulations were employed to study the effects of hydrogen segregation on dislocation plasticity of a series of symmetrical tilt grain boundaries (STGBs) with various hydrogen concentrations. Our study shows that hydrogen both enhances and reduces dislocation nucleation events from STGBs, depending on different GB structures. Specifically, for ⟨001⟩ STGBs, hydrogen does not affect the mode of heterogeneous dislocation nucleation (HDN), but facilitates nucleation events as a consequence of hydrogen disordering the GB structure. Conversely, hydrogen retards dislocation nucleation due to the fact that hydrogen segregation disrupts the transformation of boundary structure such as Σ9 (2 2 1¯) ⟨11¯0⟩ STGB. These results are helpful for deepening our understanding of GB-mediated hydrogen embrittlement (HE) mechanisms.

Rolling Contact Fatigue-Related Microstructural Alterations in Bearing Steels: A Brief Review

Bearings are vital components that are widely used in modern machinery. Although usually manufactured with high-strength steels, bearings still suffer from rolling contact fatigue where unique microstructural alterations take place beneath the contact surface as a result of the complex stress state. Studying these microstructural alterations is a hot research topic with many efforts in recent decades. In this respect, the key information regarding four major types of microstructural alterations, white etching areas/white etching cracks, dark etching regions, white etching bands and light etching regions is reviewed regarding the phenomenology and formation mechanisms. Then, classical and state-of-the-art models are established to predict their formation and are summarised and evaluated. Based on the current research progress, several key questions and paradoxes for each type of microstructural alteration are raised, suggesting possible research directions in this field.

An In-Situ Electrochemical Nanoindentation (ECNI) Study on the Effect of Hydrogen on the Mechanical Properties of 316L Austenitic Stainless Steel

In-situ electrochemical nanoindentation (ECNI) has been used to study the effect of hydrogen on the mechanical properties of austenitic stainless steel AISI 316L. Changing the electrode potential (via electrochemical charging) revealed the interconnected nature of the hydrogen effect on the nanomechanical properties of the stainless steel. At more positive cathodic potentials, a softening effect of hydrogen can be noticed, while significant hardening can be observed at more negative cathodic potentials. The hydrogen effects on the nanomechanical properties were analyzed in terms of the homogeneous dislocation nucleation (HDN) and the hydrogen-dislocation interactions from the energy point of view. The effects can be explained with the framework of the defactant theory and the hydrogen-enhanced localized plasticity (HELP) mechanism.

Molecular Dynamics Studies of Hydrogen Effect on Intergranular Fracture in α-Iron

In the current study, the effect of hydrogen atoms on the intergranular failure of α-iron is examined by a molecular dynamics (MD) simulation. The effect of hydrogen embrittlement on the grain boundary (GB) is investigated by diffusing hydrogen atoms into the grain boundaries using a bicrystal body-centered cubic (BCC) model and then deforming the model with a uniaxial tension. The Debye Waller factors are applied to illustrate the volume change of GBs, and the simulation results suggest that the trapped hydrogen atoms in GBs can therefore increase the excess volume of GBs, thus enhancing intergranular failure. When a constant displacement loading is applied to the bicrystal model, the increased strain energy can barely be released via dislocation emission when H is present. The hydrogen pinning effect occurs in the current dislocation slip system, <111>{112}. The hydrogen atoms facilitate cracking via a decrease of the free surface energy and enhance the phase transition via an increase in the local pressure. Hence, the failure mechanism is prone to intergranular failure so as to release excessive pressure and energy near GBs. This study provides a mechanistic framework of intergranular failure, and a theoretical model is then developed to predict the intergranular cracking rate.

Addressing H-Material Interaction in Fast Diffusion Materials-A Feasibility Study on a Complex Phase Steel

Hydrogen embrittlement (HE) is one of the main limitations in the use of advanced high-strength steels in the automotive industry. To have a better understanding of the interaction between hydrogen (H) and a complex phase steel, an in-situ method with plasma charging was applied in order to provide continuous H supply during mechanical testing in order to avoid H outgassing. For such fast-H diffusion materials, only direct observation during in-situ charging allows for addressing H effects on materials. Different plasma charging conditions were analysed, yet there was not a pronounced effect on the mechanical properties. The H concentration was calculated while using a simple analytical model as well as a simulation approach, resulting in consistent low H values, below the critical concentration to produce embrittlement. However, the dimple size decreased in the presence of H and, with increasing charging time, the crack propagation rate increased. The rate dependence of flow properties of the material was also investigated, proving that the material has no strain rate sensitivity, which confirmed that the crack propagation rate increased due to H effects. Even though the H concentration was low in the experiments that are presented here, different technological alternatives can be implemented in order to increase the maximum solute concentration.

Hydrogen Permeation in X65 Steel under Cyclic Loading

This experimental work analyzes the hydrogen embrittlement mechanism in quenched and tempered low-alloyed steels. Experimental tests were performed to study hydrogen diffusion under applied cyclic loading. The permeation curves were fitted by considering literature models in order to evaluate the role of trapping-both reversible and irreversible-on the diffusion mechanism. Under loading conditions, a marked shift to the right of the permeation curves was noticed mainly at values exceeding the tensile yield stress. In the presence of a relevant plastic strain, the curve changes due to the presence of irreversible traps, which efficiently subtract diffusible atomic hydrogen. A significant reduction in the apparent diffusion coefficient and a considerable increase in the number of traps were noticed as the maximum load exceeded the yield strength. Cyclic loading at a tensile stress slightly higher than the yield strength of the material increases the hydrogen entrapment phenomena. The tensile stress causes a marked and instant reduction in the concentration of mobile hydrogen within the metal lattice from 55% of the yield strength, and it increases significantly in the plastic field.

Multiscale analysis of hydrogen-induced softening in f.c.c. nickel single crystals oriented for multiple-slips: elastic screening effect

Hydrogen-deformation interactions and their role in plasticity are well accepted as key features in understanding hydrogen embrittlement. In order to understand the nature of the hydrogen-induced softening process in f.c.c. metals, a substantial effort was made in this study to determine the effect of hydrogen on the tensile stress-strain behavior of nickel single crystal oriented for multiple-slips. It was clearly established that the hydrogen softening process was the result of a shielding of the elastic interactions at different scales. Hydrogen-induced softening was then formalized by a screening factor S of 0.8 ± 0.05 for 7 wppm of hydrogen, which can be incorporated into standard dislocation theory processes. The amplitude of softening suggests that the shielding process is mainly responsible for the stress softening through the formation of vacancy clusters, rather than a direct impact of hydrogen. This effect is expected to be of major importance when revisiting the impact of hydrogen on the processes causing damage to the structural alloys used in engineering.

Quantification of Temperature Dependence of Hydrogen Embrittlement in Pipeline Steel

The effects of temperature on bulk hydrogen concentration and diffusion have been tested with the Devanathan⁻-Stachurski method. Thus, a model based on hydrogen potential, diffusivity, loading frequency, and hydrostatic stress distribution around crack tips was applied in order to quantify the temperature's effect. The theoretical model was verified experimentally and confirmed a temperature threshold of 320 K to maximize the crack growth. The model suggests a nanoscale embrittlement mechanism, which is generated by hydrogen atom delivery to the crack tip under fatigue loading, and rationalized the ΔK dependence of traditional models. Hence, this work could be applied to optimize operations that will prolong the life of the pipeline.

Study on Flake Formation Behavior and Its Influence Factors in Cr5 Steel

A flake is a crack that is induced by trapped hydrogen within steel. To study its formation mechanism, previous studies mostly focused on the formation process and magnitude of hydrogen pressure in hydrogen traps such as cavities and cracks. However, according to recent studies, the hydrogen leads to the decline of the mechanical properties of steel, which is known as hydrogen embrittlement, is another reason for flake formation. In addition, the phenomenon of stress induced hydrogen uphill diffusion should not be neglected. All of the three behaviors are at work simultaneously. In order to further explore the formation mechanism of flakes in steel, the process of flake initiation and growth were studied with the following three coupling factors: trap hydrogen pressure, hydrogen embrittlement, and stress induced hydrogen re-distribution. The analysis model was established using the finite element method, and a crack whose radius is 0.5 mm was set in its center. The cohesive method and Bilinear Traction Separate Law (BTSL) were used to address the coupling effect. The results show that trap hydrogen pressure is the main driving force for flake formation. After the high hydrogen pressure was generated around the trap, a stress field formed. In addition, the trap is the center of stress concentration. Then, hydrogen is concentrated in a distribution around this trap, and most of the steel mechanical properties are reduced. The trap size is a key factor for defining the critical hydrogen content for flake formation and propagation. However, when the trap size exceeds the specified value, the critical hydrogen content does not change any more. As for the crack whose radius is 0.5 mm, the critical hydrogen content of Cr5VMo steel is 2.2 ppm, which is much closer to the maximum safe hydrogen concentration of 2.0 ppm used in China. The work presented in this article increases our understanding of flake formation and propagation mechanisms in steel.

A review of cohesive zone modelling as an approach for numerically assessing hydrogen embrittlement of steel structures

Simulation of hydrogen embrittlement (HE) requires a coupled approach; on one side, the models describing hydrogen transport must account for local mechanical fields, while, on the other side, the effect of hydrogen on the accelerated material damage must be implemented into the model describing crack initiation and growth. This study presents a review of coupled diffusion and cohesive zone modelling as a method for numerically assessing HE of a steel structure. While the model is able to reproduce single experimental results by appropriate fitting of the cohesive parameters, there appears to be limitations in transferring these results to other hydrogen systems. Agreement may be improved by appropriately identifying the required input parameters for the particular system under study.This article is part of the themed issue 'The challenges of hydrogen and metals'.