A computational framework to predict weld integrity and microstructural heterogeneity: Application to hydrogen transmission
We present a novel computational framework to assess the structural integrity of welds. In the first stage of the simulation framework, local fractions of microstructural constituents within weld regions are predicted based on steel composition and welding parameters. The resulting phase fraction ma...
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| Language: | English |
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Elsevier
2025-01-01
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| Series: | Materials & Design |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127524009080 |
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| author | Job Wijnen Jonathan Parker Michael Gagliano Emilio Martínez-Pañeda |
| author_facet | Job Wijnen Jonathan Parker Michael Gagliano Emilio Martínez-Pañeda |
| author_sort | Job Wijnen |
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| description | We present a novel computational framework to assess the structural integrity of welds. In the first stage of the simulation framework, local fractions of microstructural constituents within weld regions are predicted based on steel composition and welding parameters. The resulting phase fraction maps are used to define heterogeneous properties that are subsequently employed in structural integrity assessments using an elastoplastic phase field fracture model. The framework is particularized to predicting failure in hydrogen pipelines, demonstrating its potential to assess the feasibility of repurposing existing pipeline infrastructure to transport hydrogen. First, the process model is validated against experimental microhardness maps for vintage and modern pipeline welds. Additionally, the influence of welding conditions on hardness and residual stresses is investigated, demonstrating that variations in heat input, filler material composition, and weld bead order can significantly affect the properties within the weld region. Coupled hydrogen diffusion-fracture simulations are then conducted to determine the critical pressure at which hydrogen transport pipelines will fail. To this end, the model is enriched with a microstructure-sensitive description of hydrogen transport and hydrogen-dependent fracture resistance. The analysis of an X52 pipeline reveals that even 2 mm defects in a hard heat-affected zone can drastically reduce the critical failure pressure. |
| format | Article |
| id | doaj-art-9e8fcfa51db949fab51062bc2cb8916b |
| institution | Kabale University |
| issn | 0264-1275 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj-art-9e8fcfa51db949fab51062bc2cb8916b2025-01-09T06:12:19ZengElsevierMaterials & Design0264-12752025-01-01249113533A computational framework to predict weld integrity and microstructural heterogeneity: Application to hydrogen transmissionJob Wijnen0Jonathan Parker1Michael Gagliano2Emilio Martínez-Pañeda3Department of Engineering Science, University of Oxford, Oxford OX1 3PJ, UKElectric Power Research Institute, 3420 Hillview Avenue, Palo Alto, CA 94304, USAElectric Power Research Institute, 3420 Hillview Avenue, Palo Alto, CA 94304, USADepartment of Engineering Science, University of Oxford, Oxford OX1 3PJ, UK; Corresponding author.We present a novel computational framework to assess the structural integrity of welds. In the first stage of the simulation framework, local fractions of microstructural constituents within weld regions are predicted based on steel composition and welding parameters. The resulting phase fraction maps are used to define heterogeneous properties that are subsequently employed in structural integrity assessments using an elastoplastic phase field fracture model. The framework is particularized to predicting failure in hydrogen pipelines, demonstrating its potential to assess the feasibility of repurposing existing pipeline infrastructure to transport hydrogen. First, the process model is validated against experimental microhardness maps for vintage and modern pipeline welds. Additionally, the influence of welding conditions on hardness and residual stresses is investigated, demonstrating that variations in heat input, filler material composition, and weld bead order can significantly affect the properties within the weld region. Coupled hydrogen diffusion-fracture simulations are then conducted to determine the critical pressure at which hydrogen transport pipelines will fail. To this end, the model is enriched with a microstructure-sensitive description of hydrogen transport and hydrogen-dependent fracture resistance. The analysis of an X52 pipeline reveals that even 2 mm defects in a hard heat-affected zone can drastically reduce the critical failure pressure.http://www.sciencedirect.com/science/article/pii/S0264127524009080Phase field fractureMulti-physics modelingWeld modelingHydrogen embrittlement |
| spellingShingle | Job Wijnen Jonathan Parker Michael Gagliano Emilio Martínez-Pañeda A computational framework to predict weld integrity and microstructural heterogeneity: Application to hydrogen transmission Materials & Design Phase field fracture Multi-physics modeling Weld modeling Hydrogen embrittlement |
| title | A computational framework to predict weld integrity and microstructural heterogeneity: Application to hydrogen transmission |
| title_full | A computational framework to predict weld integrity and microstructural heterogeneity: Application to hydrogen transmission |
| title_fullStr | A computational framework to predict weld integrity and microstructural heterogeneity: Application to hydrogen transmission |
| title_full_unstemmed | A computational framework to predict weld integrity and microstructural heterogeneity: Application to hydrogen transmission |
| title_short | A computational framework to predict weld integrity and microstructural heterogeneity: Application to hydrogen transmission |
| title_sort | computational framework to predict weld integrity and microstructural heterogeneity application to hydrogen transmission |
| topic | Phase field fracture Multi-physics modeling Weld modeling Hydrogen embrittlement |
| url | http://www.sciencedirect.com/science/article/pii/S0264127524009080 |
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