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The Effect of Microstructural Variation on the Hydrogen Environment-Assisted Cracking of Monel K-500

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Abstract

The influence of microstructural variation on hydrogen environment-assisted cracking (HEAC) of Monel K-500 was evaluated using five nominally peak-aged lots of material tested under slow-rising stress intensity loading while immersed in NaCl solution under cathodic polarizations. Minimal variation in HEAC resistance among material lots was observed for an applied potential of −950 mVSCE (E app, vs saturated calomel), whereas lot-to-lot variability in the fracture morphology demonstrates a significant difference in the HEAC resistance at the less negative potential of −850 mVSCE, suggesting that relatively severe H environments produce sufficient crack-tip H to minimize the impact of metallurgical differences. Sensitivity analyses accomplished by varying the inputs used in decohesion-based, micromechanical models imply significant variations in HEAC resistance are possible for realistic changes in grain boundary toughness, hydrogen uptake behavior, and yield strength. Grain size, impurity segregation (including the effects of gettering elements), grain boundary character/connectivity, and crack path tortuosity are also considered in the context of HEAC susceptibility. Yield strength, global hydrogen content, as well as impurity segregation to grain boundaries, especially boron and sulfur, are speculatively considered to be the dominant contributions in determining HEAC resistance. Modifications that would incorporate the effects of grain boundary segregation are proposed for the K TH model; detailed validation of such changes require high-fidelity and quantitative inputs for the degree of grain boundary segregation. Regardless, fracture mechanics-based HEAC results, detailed microstructural characterization, and micromechanical modeling were successfully coupled to gain insights into the influences governing the microstructure-dependent HEAC susceptibility of Monel K-500.

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Notes

  1. HEAC testing of the component specimens were performed in the as-received conditions. A companion study suggests that H-charging that occurred during field service may lead to a total internal H-concentration, CH-total, on the order of 5 wppm which is similar to the 6 wppm at the crack tip at −850 mVSCE obtained for the Allvac material lot.[18] The effects of the precharged hydrogen is discussed in more detail elsewhere.[124] However, HEAC testing of the component specimens in an inert environment did not show H-enhanced IG cracking due to the precharged H-content.

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Acknowledgments

This research was sponsored by the Office of Naval Research (ONR) Grant N00014-12-1-0506 with Dr. Airan Perez as Scientific Officer. Helpful discussions with Professor Richard Gangloff and fracture mechanics testing by Ms. Christina Kaminksy are gratefully acknowledged. Z.D.H. gratefully acknowledges the support of the ALCOA Graduate Fellowship.

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Author notes

  1. Justin D. Dolph (Graduate Student, Staff Engineer)

    Present address: Elzly Technology Corporation, Reston, VA, 20190, USA

  2. Greger L. Pioszak (Graduate Student, Senior Materials Engineer)

    Present address: Exxon Mobil Corporation, Houston, TX, 77386, USA

Authors and Affiliations

  1. Center for Electrochemical Science and Engineering, Department of Materials Science and Engineering, University of Virginia, Charlottesville, VA, 22904, USA

    Zachary D. Harris (Graduate Student), Justin D. Dolph (Graduate Student, Staff Engineer), Greger L. Pioszak (Graduate Student, Senior Materials Engineer), Brendy C. Rincon Troconis (Research Associate), John R. Scully (Charles Henderson Chaired Professor of Materials Science and Engineering) & James T. Burns (Assistant Professor)

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Manuscript submitted December 21, 2015.

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Harris, Z.D., Dolph, J.D., Pioszak, G.L. et al. The Effect of Microstructural Variation on the Hydrogen Environment-Assisted Cracking of Monel K-500. Metall Mater Trans A 47, 3488–3510 (2016). https://doi.org/10.1007/s11661-016-3486-7

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