An experimental and statistical study on the characteristics of non-metallic inclusions that serve as hydrogen-induced crack nucleation sites in pipeline steel

This study consists of a statistical study to identify spatial distribution parameters of non-metallic inclusions (NMIs) at hydrogen-induced cracking (HIC) nucleation sites in both low-strength and high-strength steel pipes. The electrochemical cathodic charging method was used to induce HIC in pipeline steel plates, and the nucleation of the HIC was monitored using straight beam ultrasonic testing. Optical microscopy (OM) and scanning electron microscopy (SEM) were used to evaluate the shape, size, area fraction, and separation distance of NMIs. The hydrogen microprint technique (HMT), electron backscattered diffraction (EBSD) analysis, and finite element (FE) stress analysis were performed to characterize HIC nucleation sites. The findings showed that cubical and spinal NMIs, characterized by strong hydrogen trapping capacity due to high misfit strain and von Mises stress, are favored sites for HIC nucleation. The main finding of this study is that the shape and sharpness of NMIs are the factors that determine when NMIs will be a HIC nucleation site, rather than size, as generally accepted.