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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Hydrogen embrittlement and mechanical response of 304L steel with ZrC additions

While stainless steels are widely used for hydrogen storage infrastructure, they can still be vulnerable to hydrogen embrittlement justifying the need to further improve their hydrogen resiliency. Here, we investigate the potential for transition metal carbide additions to improve the hydrogen compatibility of austenitic stainless steels. ZrC nanoparticles were dispersed in contents of 0.01–10 wt% in 304 L stainless steel powder, mixed via high energy ball milling, and subsequently consolidated using direct current sintering. To assess hydrogen compatibility, the tensile properties of similarly processed 304 L without ZrC nanoparticles were compared to 304 L with the ZrC additions; both materials were evaluated prior to and after hydrogen exposure (non-charged and H-precharged, respectively). Depending upon the ZrC phase fraction, the yield strengths varied from ∼325 to 560 MPa in the non-charged condition and from ∼375 to 550 MPa in the H-precharged condition. Strain at failure varied from ∼5 to 90 % and from ∼5 to 35 % in the non-charged and hydrogen-precharged conditions, respectively. Results from stress-strain profiles demonstrate limited efficacy of ZrC as a method to mitigate hydrogen embrittlement entirely but does demonstrate the potency of ZrC inclusions as strengthening addition to 304 L alloys without a loss of ductility.

08 HYDROGEN↗
DOE OSTI2026

Assessment of Vibration and Shock Loading Environments on Steels Used in Railroad Applications Considering Hydrogen Embrittlement

Studies that examine the combined effects of hydrogen and rail loading environments in the context of hydrogen embrittlement of steels have not been performed. Large-scale hydrogen storage requires either gaseous hydrogen stored in pressure vessels and tubing or liquid hydrogen in cryogenic, insulated tanks. Since the focus of this study is on steels, we examine the influence of hydrogen on stainless steel used for high pressure tubing and cryogenic tanks and Cr-Mo steel liners used in gaseous pressure vessels. Literature studies show that despite hydrogen degradation, these steels can be used effectively and safely if the stresses are managed. The shock and vibration environment on railcars present unique environments where stresses and loading rates can be high. A literature review was conducted to understand the accelerations experienced in rail by examining instrumented railcars of nuclear fuel casks. Hydrogen studies were examined that focused on steel pressure hardware with an emphasis on fatigue, fast loading rates, and low temperatures. A simplified fatigue assessment was performed to examine design cycles for three different hydrogen components: stainless steel tubing, stainless steel cryogenic tanks, and gaseous pressure vessels. The assessments were idealized and used bounding cases of accelerations in both normal rail conditions and coupling events. In normal shock and vibration environments when accelerations were less than 2 g, infinite design life was calculated. In extreme shock or coupling environments, finite design life was calculated which was shown to be dependent on unsupported lengths of pressure components. It was shown that adjusting the unsupported length can reduce the bending stress thereby increasing design life.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Gaseous Hydrogen Embrittlement of L-PBF Ni-Based Superalloys for Service in Natural Gas Turbines

Efforts to improve efficiency of industrial gas turbine engines have focused on increasing operating temperatures by use of fuel-flexible gas blends. Ni-based superalloys are susceptible to hydrogen embrittlement (HE), leading to potential risk of premature component failure. Certain turbine components exposed to hydrogen-rich environments are manufactured from additive processes like laser powder bed fusion (L-PBF). The HE susceptibility was evaluated for three Ni-based superalloys: solid solution strengthened Alloy 625, γ’/γ’’-precipitation strengthened Alloy 718, and γ’-precipitation strengthened Haynes® 282®. L-PBF samples were pre-charged under medium and high pressure gaseous hydrogen before tensile testing at temperatures up to 260 °C using a fast strain rate. Selected samples were subjected to a service conditioning heat treatment prior to hydrogen charging to evaluate the change in susceptibility after prolonged service. The susceptibility to HE and HE mechanisms of these three alloys is compared.

additive manufacturing↗
DOE OSTI2024

Hydrogen embrittlement of Zircaloy-4 fabricated by ultrasonic additive manufacturing

Ultrasonic additive manufacturing (UAM) was successfully applied to the zirconium material system to create a planar geometry. Following fabrication, SS-J3 type tensile specimens of the UAM and wrought Zircaloy-4 with a nominal gage section of 5×1.2×0.75 mm were machined for hydriding studies and mechanical testing. The SS-J3 type tensile specimens were gas-charged with hydrogen using a custom system that precisely controls hydrogen gas flow rate, hydrogen partial pressure, and temperature. To avoid altering the UAM material, the maximum process temperature was limited to 550°C. Using different initial hydrogen gas pressures and flow rates, various hydrogen contents (70–1755 wppm) were achieved for Zircaloy-4 specimens. Tensile testing shows that, regardless of hydrogen content, all UAM specimens measured yield strengths in the range of 557±16 MPa and ultimate tensile strengths of 660±4MPa. However, total elongation clearly decreased as a function of increasing hydrogen content. Further, at the lowest hydrogen content, the total plastic elongation measured 21.5%, and this value decreased to less than 2% when the hydrogen content was increased to 1000 wppm. Cross-sectional optical microscopy images revealed that the hydride distributions are randomly oriented. For the low hydrogen content specimen, these randomly distributed hydrides are isolated from each other. A sandwiched structure, consisting of high-density and low-density layers, was also observed for the specimens with hydrogen content between 200 and 400 wppm. As the hydrogen content increases, the hydrides diffuse into the low-density hydride layers to form a network across the whole specimen. Although the tensile properties of UAM and wrought Zircaloy-4 exhibit the same behavior with increasing hydrogen content, the distinctions in grain orientations led to differences in the hydride orientations at low and intermediate hydrogen concentrations.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Direct observation of strain-enhanced hydrogen segregation and failure at high-angle grain boundaries in nickel

Understanding the mechanisms underlying hydrogen embrittlement remains difficult, even in single-element metals. Both microstructure and stress state influence hydrogen distribution in metals and alloys, which impacts deformation and failure. Here, in this work, we use in-situ Kelvin probe force microscopy (KPFM) to monitor the hydrogen distribution in pure nickel over time at 1.1 % and 3.5 % strain. The sample strained to 3.5 % results in preferential hydrogen segregation to high-angle grain boundaries whereas the sample strained to 1.1 % does not exhibit preferential hydrogen segregation. Optical digital image correlation (DIC) shows that hydrogen charging results in both localized and reduced strains during tensile testing of a notched sample. Later stages of deformation and failure (e.g. microcracking) are studied by using in-situ transmission X-ray microscopy (TXM). TXM reveals nanoscale structural changes to a propagating crack in a hydrogen environment. Localized void growth and secondary cracking occur at grain boundaries near the primary crack front. Correlative electron backscattering diffraction (EBSD) is used to relate the cracking at grain boundaries to the hydrogen segregation observed in KPFM. These findings are unified in a proposed hydrogen embrittlement mechanism that describes the interaction of hydrogen with grain boundaries, and the role of grain boundaries in hydrogen embrittlement.

Grain boundary fracture↗
DOE OSTI2024

Microstructural Engineering and Accelerated Test Method Development to Achieve Low Cost, High Performance Solutions for Hydrogen Storage and Delivery

This project made advancements in developing lower cost steel alloys with novel microstructural design for use in hydrogen refueling infrastructure such as storage, compressors, and dispensing components, and utilizing accelerated test methods to efficiently evaluate variations in alloy and microstructure design. The project specifically sought to design alloys with lower nickel contents to reduce alloy cost, which was accomplished through substituting manganese for nickel along with other alloy additions to control deformation characteristics known to be important for hydrogen embrittlement resistance. Through Mn substitutions for nickel, austenitic and duplex austenite-ferrite steels were successfully developed with lower cost than currently available commercial stainless steel products that are employed for hydrogen refueling infrastructure. The steels were processed to achieve comparable strength and toughness in hydrogen environments as the commercially available steels containing high Ni contents. To evaluate mechanical performance in hydrogen, a testing methodology was employed to compare ubiquitous laboratory testing using electrochemical hydrogen charging in a liquid electrolyte to less accessible high pressure gaseous testing. While the application of these steels is in high pressure gaseous environments, the electrochemical hydrogen charging tests produced comparable results. Additionally, the Los Alamos Neutron Scatting Center enabled characterization of deformation mechanisms of the steel alloys in the presence of hydrogen, which has been associated with steel alloy characteristics associated with hydrogen embrittlement. Finally, a fracture mechanics based test bed model was developed to predict the influence of hydrogen gas pressure and fatigue conditions on fatigue lifetimes of pressure vessel steels. Together, these developments can be employed to enable lower cost hydrogen fueling infrastructure and more reliable prediction of steel alloy components in hydrogen service conditions. In particular, the newly alloys have the potential to replace stainless steels, having demonstrated comparable performance at substantially reduced cost.

08 HYDROGEN↗
DOE OSTI2025

Dislocation nano-hydrides in nickel: Nucleation, evolution and effects on dislocation behaviors

Nano-hydrides have been predicted to precipitate at the core of edge dislocations in the Ni-H system, a mechanism that may promote hydrogen embrittlement. However, nano-hydride nucleation, growth, and effects on dislocation behavior have seldom been explored. This work combines molecular dynamics grand canonical Monte Carlo (MD-GCMC) simulations and continuum modeling to uncover a wide range of phenomena linked to dislocation nano-hydrides. Simulations reveal that nano-hydrides can be stabilized at dislocation cores with all character angles, including screw segments, due to the hydrostatic stresses around the cores of the Shockley partials. Nano-hydride nucleation takes place in these regions, and growth is dictated by the character angle θ of the perfect dislocation. The equilibrium stacking fault width d eq varies dynamically to increase the local hydrostatic stress field and facilitate the formation of the nano-hydride, forming a constriction-like feature and leading to three distinct behaviors: d eq decreases for θ > 30°, d eq remains unchanged for θ = 30°, and d eq increases for θ < 30°. Remote hydrostatic and Escaig stresses are also shown to influence the nucleation stage, implying stress concentrations such as those ahead of crack tips may facilitate nano-hydride precipitation. Moreover, we identify a new hydrogen-induced 60° dislocation reaction that emits a Shockley partial on a conjugate plane, with potential implications for twin nucleation. Testable predictions from this study are then used to reinterpret previous results from the literature. In conclusion, these findings provide a comprehensive framework to assess nano-hydride formation and evolution at dislocations in nickel and other face-centered cubic metals, with important implications to hydrogen embrittlement.

Dislocations↗
DOE OSTI2025

Comments on “Failure analysis of corroded hydrogen-blended natural gas pipelines based on finite element analysis and genetic algorithm-back propagation neural network” [262 (2025) 111174]

This is a brief commentary paper to highlight and discuss the determination of hydrogen concentration in pipeline steel, effect of hydrogen embrittlement (HE) on the mechanical properties of the material, burst strength of corroded pipelines using finite element analysis (FEA) simulations, and curve-fit models for assessing remaining strength of X80 corroded pipelines for transporting hydrogen blended natural gas. Recently, Xie et al. [1] proposed a methodology to quantify the impact of HE on material properties and numerically determined burst pressure of X80 corroded pipelines. However, their HE quantification overestimated the degradation of tensile strength for hydrogen blending ratios beyond the original data range, and their FEA results of burst pressure are nonconservative. This work thus recharacterized the hydrogen concentration in the steel pipeline and the effect of HE on tensile strength, and then redetermined burst pressures for a set of typical corrosion defect cases considered by Xie et al. [1] based on an experimentally validated FEA modelling method. With the new FEA results, two empirical corrosion models were proposed for X80 corroded pipelines for hydrogen service. At zero hydrogen blending ratio, the novel empirical models predict burst pressures to be consistent with the industry-accepted corrosion models. Furthermore, both the numerical simulation method and the novel corrosion models are significant contributions to the pipeline industry and the hydrogen community. Application of these results will enhance the safety, reliability, and integrity of natural gas pipelines when used to transport hydrogen.

Burst pressure prediction↗
DOE OSTI2025

Influence of stacking fault energy and hydrogen on deformation mechanisms in high Mn austenitic steels during in-situ tensile testing

High Mn austenitic steels are considered an economical alloy system for hydrogen storage and transport applications. This study used stacking fault energy (SFE) as a design parameter to achieve hydrogen embrittlement (HE)-resistant high Mn austenitic alloys. The role of hydrogen on the deformation mechanisms of low (29 mJ/m 2 ) and high SFE (49 mJ/m 2 ) alloys was evaluated through in-situ neutron diffraction during tensile loading. Hydrogen-precharging increased yield strength, partly due to hydrogen-induced lattice distortion (i.e., solute strengthening). Hydrogen accelerated the increase in defect density, including dislocations and stacking faults. The formation of planar deformation structures (twins and stacking faults), relative to dislocations, plays a critical role in promoting hydrogen-assisted fracture. The stacking fault frequency parameter obtained from neutron diffraction quantifies planar deformation tendencies, correlated with HE sensitivity. The higher SFE alloy exhibited greater resistance to HE, associated with the reduced propensity to form stacking faults and twins upon deformation in the hydrogen-precharged condition.

High Mn austenitic steel↗
DOE OSTI2025

Direct Imaging of Hydrogen‐Driven Dislocation and Strain Field Evolution in a Stainless Steel Grain

Hydrogen embrittlement (HE) poses a significant challenge to the durability of materials used in hydrogen production and utilization. Disentangling the competing nanoscale mechanisms driving HE often relies on simulations and electron-transparent sample techniques, limiting experimental insights into hydrogen-induced dislocation behavior in bulk materials. This study employs in situ Bragg coherent X-ray diffraction imaging to track three-dimensional (3D) dislocation and strain field evolution during hydrogen charging in a bulk grain of austenitic 316 stainless steel. Tracking a single dislocation reveals hydrogen-enhanced mobility and relaxation, consistent with dislocation dynamics simulations. Subsequent observations reveal dislocation unpinning and climb processes, likely driven by osmotic forces. Additionally, nanoscale strain analysis around the dislocation core directly measures hydrogen-induced elastic shielding. These findings experimentally validate theoretical predictions and offer mechanistic insights into hydrogen-driven dislocation behavior. The quantified nanoscale phenomena serve as critical inputs for multiscale modeling frameworks to predict bulk material responses and accelerate the development of HE-resistant alloys.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Recent Advances in Pipeline Integrity for Transporting Blended Hydrogen-Natural Gas

To achieve US decarbonization goals, hydrogen is being considered as an alternative energy source to reduce carbon emissions. Blending hydrogen into existing natural gas pipelines is an intuitive first step to enable near term emission reductions. However, there are numerous challenges and uncertainties that complicate the transition to transporting hydrogen long-distance through existing natural gas pipelines. The main challenge is hydrogen embrittlement (HE), which reduces the ductility, fracture toughness and fatigue resistance of pipeline steels. This work delivers a technical review on HE effects on the material properties of pipeline carbon steels, such as Grade B, X52, X65, X70, X80, and X100. An important aspect of laboratory tests to capture the HE effect is the hydrogen test environment. This includes hydrogen pre-charged specimens tested in air and specimens tested in a hydrogen gas environment. A review of the mechanical properties of pipeline steel in different hydrogen environments determined through tensile testing is given first, which includes HE effects on yield strength, ultimate tensile strength, and ductility for blended hydrogen-natural gas pipelines. Then, the HE effects on fracture toughness and fatigue crack growth resistance are discussed. Last, impacts of HE to pipeline integrity and major technical challenges are discussed.

: Hydrogen Embrittlement↗
DOE OSTI2025

Interplay between hydrogen, temperature, and character angle on dissociated dislocation energies in Fe–Ni–Cr austenitic stainless steels

Dislocation energy has an important role in the mechanical performance of structural metals. While dislocation energies cannot be fully obtained from continuum theories due to the contribution of the dislocation core, they have been calculated via atomistic simulations in elemental metals. However, constraints on the local atomic environments have prevented the use of such approaches in systems that incorporate alloying or interstitial solutes. In this work, we develop robust molecular dynamics methods to resolve these issues through a geometric construction of dislocation dipoles and the calculation of time-averaged energies. Furthermore, we apply these methods to calculate dislocation energies (including core energies) in an Fe 70 Ni 11 Cr 19 austenitic steel at a variety of character angles, hydrogen concentrations, temperatures, and dipole spacings. The resulting highly converged energies show an excellent agreement with continuum expressions. Overall, hydrogen concentrations up to 1.0 % do not have a significant effect on the elastic parameters and dislocation energy. The methods and insights derived in this work have the potential to facilitate the calculation of dislocation energies in a wide range of systems, and to guide our understanding of hydrogen embrittlement.

Alloyed systems↗
DOE OSTI2025

Hydrogen and water interactions with CrMnFeCoNi alloy from density functional theory calculations

High entropy alloys (HEAs) are a promising class of materials with remarkable mechanical and catalytic properties. Among these, the quinary CrMnFeCoNi alloy (also called “Cantor alloy”) has attracted considerable attention given its thermodynamic stability and remarkable mechanical properties under different temperatures. Given that various degradation mechanisms involve multiple contaminants, such as hydrogen and water in hydrogen embrittlement and surface poisoning, respectively, understanding their interactions with the Cantor alloy is critical for its practical applications as structural, nuclear, or hydrogen storage material. In this work, we perform first-principles calculations based on Density Functional Theory (DFT) to investigate such interactions when considering various microstructures, including bulk materials and those containing certain defects, such as grain boundaries, stacking faults, and vacancies. We also employ Global Sensitivity Analysis to identify the importance of different factors in the stability of the impurities. We find that the accuracy of the H formation energy is significantly affected by spin polarization and chemical short-range order. The study also identifies a strong tendency for hydrogen interstitials to segregate to Σ5(210)/[001] symmetric tilt grain boundary, even when H concentrations are high, suggesting that a certain type of grain boundaries acts as H sinks within the alloy. Further, this result is reinforced by the low formation energy of vacancy-hydrogen complexes, which can contain multiple hydrogen atoms. Finally, the surface reactivity analysis reveals that the adsorption energy of oxygen and hydroxyl groups is highly sensitive to the specific metal atom involved in the binding, with a clear preference for chromium atoms, which could have implications for the alloy’s oxidation and corrosion behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2025

An energetic link between order and strength in metals: A nanocrystalline strength limit in high-entropy alloys and intermetallic compounds

The metallurgy and materials communities have long understood and exploited fundamental links between chemical and structural ordering in metallic solids to tailor their mechanical properties. We extend these ideas to include prediction of the nanocrystalline strength limit in high-entropy alloys and intermetallic compounds, where a breakdown occurs in the classical Hall-Petch strengthening behavior. The highest reported strength achievable through alloying has rapidly climbed and given rise to new classifications of materials with extraordinary properties, with a notable case being nanocrystalline metals. High-entropy alloys (chemically disordered, concentrated solid solutions) and intermetallic compounds are two boundary cases of how tailored order can be used to manipulate mechanical behavior. Here, we show that the complex electronic-structure mechanisms governing the peak strength of alloys and pure metals can be reduced to a few physically meaningful parameters based on their atomic arrangements and used – with no fitting parameters – to predict the maximum strength of these materials. This includes a generalized energy-based accounting for the degree of structural and chemical ordering that allows for rapid and reasonably accurate prediction of peak strength (validated in the nanocrystalline limit) as a function of temperature. Predictions of maximum strength based on the activation energy (with all materials properties derived from DFT calculations or experiments) for a stress-driven transition to an amorphous state is shown to accurately describe the breakdown in Hall-Petch behavior at the smallest crystallite sizes for pure metals, intermetallic compounds, high-entropy alloys, and metallic glasses. Further, this activation energy is also shown to be directly proportional to interstitial electronic charge density, which is a good predictor of ductility, stiffness (moduli), and phase stability in high-entropy alloys and solid metals generally. The proposed framework suggests the possibility of coupling ordering and intrinsic strength to mechanisms like dislocation nucleation, hydrogen embrittlement, and transport properties, such as through correlations between the activation energies for amorphization with stacking-fault and grain boundary energies. It additionally opens the prospect for greatly accelerated structural materials design and development to address materials challenges limiting more sustainable and efficient use of energy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Logical approach to tritium vacuum pump selection for fusion applications

Vacuum pumps have been used for tritium processing since the 1940s following the isolation of pure tritium. The largest problem facing tritium vacuum pumps is the tritium radioactive decay. The beta particles, recoil energy, and subsequent radical formations are detrimental to most carbon-based materials. Carbon materials, such as plastics, elastomers, carbon fiber, activated carbon, etc., react with tritium to form methane and in the process strip material from the carbonbased material. Other reactions can be self-catalyzing, as is the case with nitrogen and tritium forming tritiated ammonia at room temperature and pressure. Tritium also readily isotopically exchanges with surface -OH groups, increasing the amount of protium in the gas stream while creating a tritium holdup on the surface. Metals are the preferred material when working with tritium, but tritium will permeate into and through almost all metals at some point. The entrapped tritium can decay inside the metal, creating local helium distortions that can impact the structural properties above and beyond the hydrogen embrittlement issue tritium can cause.

Angelette, Lucas M. [Savannah River National Labor↗
DOE OSTI2025

CRADA 2022-03 Final Report: Advanced Bearing Materials for Harsh Service Conditions

Develop advanced bearing materials for hydrogen gas turbines and wind turbines. Two candidate materials have been selected based on Ames lab’s recent work on high entropy alloys and shape memory alloys. These materials are designed to exhibit a balance of hardness, strength, toughness, and corrosion resistance. The hydrogen diffusion coefficient in the NiTi based shape memory alloy is two order of magnitude lower than that of the conventional case hardened bearing steel. We plan to atomize these materials into powders, additive manufacture cylindrical bearings, then test these bearing for rolling-contact fatigue, corrosion properties, and hydrogen embrittlement. We are a vertically integrated team comprises of national labs, bearing manufacturers, raw material powders makers, and aircraft gas turbine manufacturer.

Argibay, Nicolas [Ames Laboratory (AMES), Ames, IA↗