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Methodology for Hydrogen-Assisted Fatigue Testing Using In Situ Cathodic Charging.

Kai Donnerbauer1, Timo Nickel1, Matthias von Pavel1,2

  • 1Chair of Materials Test Engineering (WPT), TU Dortmund University, Baroper Str. 303, D-44227 Dortmund, Germany.

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Summary

This study developed a novel electrochemical method for testing materials under hydrogen exposure and mechanical stress. Results show hydrogen significantly reduces fatigue life in AISI 4140 steel, altering crack initiation in higher strength conditions.

Keywords:
AISI 4140electrochemical hydrogen chargingfatigue engineeringfractographyhydrogen embrittlementin situ cathodic hydrogen charging

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Electrochemistry

Background:

  • Hydrogen is crucial for energy applications, necessitating reliable material testing under combined mechanical load and hydrogen exposure.
  • High-pressure gaseous hydrogen presents cost and safety challenges for material testing.
  • Electrochemical hydrogen charging offers a safer, more cost-effective alternative.

Purpose of the Study:

  • To develop and validate a novel testing setup for evaluating material performance under superimposed mechanical loading and electrochemical hydrogen charging.
  • To characterize the fatigue behavior of AISI 4140 steel in different heat-treated conditions when exposed to hydrogen.
  • To investigate the influence of hydrogen on fatigue life and crack initiation mechanisms.

Main Methods:

  • A customized electrochemical charging cell integrated into a dynamic testing system was employed.
  • Constant amplitude fatigue tests were conducted on two heat treatment states of AISI 4140 steel.
  • In situ cathodic hydrogen charging was performed during fatigue testing, with comparative tests in air.

Main Results:

  • S-N (Woehler) curves demonstrated distinct fatigue behaviors for the different heat-treated states of AISI 4140.
  • In situ cathodic hydrogen charging significantly reduced the fatigue life of both material states compared to testing in air.
  • Fractographic analysis revealed altered crack initiation mechanisms in the higher strength heat treatment state under hydrogen charging.

Conclusions:

  • The developed electrochemical setup effectively simulates hydrogen charging under mechanical load for material testing.
  • Hydrogen embrittlement demonstrably reduces fatigue life in AISI 4140 steel, with a more pronounced effect on crack initiation in higher strength conditions.
  • This method provides a viable alternative for assessing hydrogen effects on materials in energy-related applications.