Pub Date : 2025-12-30DOI: 10.1016/j.ijpvp.2025.105739
Feng Yu , Jian Fang , Mingcheng Sun , Feng Zhang , Jianwei Zhang , Yingzhi Li
To address the demand for rapid, non-destructive, and accurate characterization of ultra-high-strength oil casing steels in H2S-containing environments, this study combined standard tests with the instrumented spherical indentation test (ISIT) to evaluate the tensile properties, fracture toughness, and post-hydrogen-induced cracking (HIC) performance of three XCoMo-series steels (Q125, Q140, Q165). Key findings: 1) The three steels broke the strength-toughness trade-off, with Q165 showing the best performance due to the synergy of grain refinement and alloy strengthening. 2) Validated against ISO standards, ISIT achieved prediction errors of ≤10 % for yield stress, ≤5 % for ultimate tensile stress, and ≤15 % for fracture toughness, enabling non-destructive, and rapid in-situ characterization. 3) After HIC exposure, all three steels showed an elastic modulus decrease of ≥25.4 % with grade-specific strength response characteristics, while Q165 maintained the smallest fracture toughness reduction (3.3 %). Notably, ISIT realized quantitative characterization of HIC-induced performance degradation, successfully filling the evaluation gap of traditional HIC tests and providing direct data support for performance degradation assessment.
{"title":"Assessment of tensile properties and fracture toughness of ultra-high-strength oil casing steels via instrumented spherical indentation test","authors":"Feng Yu , Jian Fang , Mingcheng Sun , Feng Zhang , Jianwei Zhang , Yingzhi Li","doi":"10.1016/j.ijpvp.2025.105739","DOIUrl":"10.1016/j.ijpvp.2025.105739","url":null,"abstract":"<div><div>To address the demand for rapid, non-destructive, and accurate characterization of ultra-high-strength oil casing steels in H<sub>2</sub>S-containing environments, this study combined standard tests with the instrumented spherical indentation test (ISIT) to evaluate the tensile properties, fracture toughness, and post-hydrogen-induced cracking (HIC) performance of three XCoMo-series steels (Q125, Q140, Q165). Key findings: 1) The three steels broke the strength-toughness trade-off, with Q165 showing the best performance due to the synergy of grain refinement and alloy strengthening. 2) Validated against ISO standards, ISIT achieved prediction errors of ≤10 % for yield stress, ≤5 % for ultimate tensile stress, and ≤15 % for fracture toughness, enabling non-destructive, and rapid in-situ characterization. 3) After HIC exposure, all three steels showed an elastic modulus decrease of ≥25.4 % with grade-specific strength response characteristics, while Q165 maintained the smallest fracture toughness reduction (3.3 %). Notably, ISIT realized quantitative characterization of HIC-induced performance degradation, successfully filling the evaluation gap of traditional HIC tests and providing direct data support for performance degradation assessment.</div></div>","PeriodicalId":54946,"journal":{"name":"International Journal of Pressure Vessels and Piping","volume":"221 ","pages":"Article 105739"},"PeriodicalIF":3.5,"publicationDate":"2025-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145876934","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-26DOI: 10.1016/j.ijpvp.2025.105734
You Li , Bieerlan Jianayihan , Zhenyu Wang , Peng Jiao , Chaoxu Guan , Hao Huang
2.25Cr1Mo0.25V steel is widely adopted in critical high-temperature components across the petrochemical and power energy sectors. Owing to extended service under harsh conditions, creep rupture emerges as the primary failure mode encountered in this steel. However, the limited availability of creep data significantly constrains the efficacy of conventional empirical and data-driven techniques in accurately predicting the creep life of 2.25Cr1Mo0.25V steel. To address this issue, a novel methodology was introduced for predicting the creep life of 2.25Cr1Mo0.25V steel, utilizing cross-material transfer learning (TL), automatic hyperparameter optimization (auto-HPO), and Bagging ensemble techniques. Here, three TL strategies were developed and evaluated: a baseline network, a variant augmented with weight coefficients (W-TL network), and a dual-enhanced model incorporating both weight coefficients and residual connections (W-Res-TL model). Meanwhile, four auto-HPO algorithms—Random, TPE, Naive Evolution, and Anneal—were implemented over an extensive hyperparameter search space. During the auto-HPO process, the performance of TL was evaluated through 5-fold cross-validation, utilizing Smooth L1 Loss as the metric. Results demonstrated that the W-Res-TL network, when integrated with Naive Evolution, exhibits superior performance. Thus, an ensemble comprising 100 instances of this network was developed. The resulting Bagging model was systematically discussed with respect to accuracy, extrapolation performance, and SHAP-based interpretability. Accuracy assessment showed that the W-Res-TL Bagging model consistently attains high predictive precision on both the training and test sets. Extrapolation analysis suggested that the W-Res-TL Bagging model demonstrates strong generalization capabilities across a broad spectrum of temperatures and stresses, without yielding any non-physical results. SHAP analysis substantiated the model's interpretability by elucidating the contribution of input features to its predictions. Moreover, the performance of proposed creep life modeling framework was demonstrated to surpass that of the traditional Larson-Miller method as well as six widely employed machine learning (ML) algorithms. This can be attributed to the effective capability of the W-Res-TL approach in capturing and transferring the inherent creep knowledge of CrMo steels to 2.25Cr1Mo0.25V steel. This study can facilitate the accurate and rapid prediction of creep life for materials characterized by scarce creep data.
{"title":"Creep life prediction of 2.25Cr1Mo0.25V steel using cross-material transfer learning, automatic hyperparameter optimization, and Bagging ensemble","authors":"You Li , Bieerlan Jianayihan , Zhenyu Wang , Peng Jiao , Chaoxu Guan , Hao Huang","doi":"10.1016/j.ijpvp.2025.105734","DOIUrl":"10.1016/j.ijpvp.2025.105734","url":null,"abstract":"<div><div>2.25Cr1Mo0.25V steel is widely adopted in critical high-temperature components across the petrochemical and power energy sectors. Owing to extended service under harsh conditions, creep rupture emerges as the primary failure mode encountered in this steel. However, the limited availability of creep data significantly constrains the efficacy of conventional empirical and data-driven techniques in accurately predicting the creep life of 2.25Cr1Mo0.25V steel. To address this issue, a novel methodology was introduced for predicting the creep life of 2.25Cr1Mo0.25V steel, utilizing cross-material transfer learning (TL), automatic hyperparameter optimization (auto-HPO), and Bagging ensemble techniques. Here, three TL strategies were developed and evaluated: a baseline network, a variant augmented with weight coefficients (W-TL network), and a dual-enhanced model incorporating both weight coefficients and residual connections (W-Res-TL model). Meanwhile, four auto-HPO algorithms—Random, TPE, Naive Evolution, and Anneal—were implemented over an extensive hyperparameter search space. During the auto-HPO process, the performance of TL was evaluated through 5-fold cross-validation, utilizing Smooth L1 Loss as the metric. Results demonstrated that the W-Res-TL network, when integrated with Naive Evolution, exhibits superior performance. Thus, an ensemble comprising 100 instances of this network was developed. The resulting Bagging model was systematically discussed with respect to accuracy, extrapolation performance, and SHAP-based interpretability. Accuracy assessment showed that the W-Res-TL Bagging model consistently attains high predictive precision on both the training and test sets. Extrapolation analysis suggested that the W-Res-TL Bagging model demonstrates strong generalization capabilities across a broad spectrum of temperatures and stresses, without yielding any non-physical results. SHAP analysis substantiated the model's interpretability by elucidating the contribution of input features to its predictions. Moreover, the performance of proposed creep life modeling framework was demonstrated to surpass that of the traditional Larson-Miller method as well as six widely employed machine learning (ML) algorithms. This can be attributed to the effective capability of the W-Res-TL approach in capturing and transferring the inherent creep knowledge of CrMo steels to 2.25Cr1Mo0.25V steel. This study can facilitate the accurate and rapid prediction of creep life for materials characterized by scarce creep data.</div></div>","PeriodicalId":54946,"journal":{"name":"International Journal of Pressure Vessels and Piping","volume":"220 ","pages":"Article 105734"},"PeriodicalIF":3.5,"publicationDate":"2025-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145883897","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-26DOI: 10.1016/j.ijpvp.2025.105738
Fuhai Gao , Cheng Li , Rou Du , Jianguo Gong , Xiaoming Liu , Fuzhen Xuan
2.25Cr–1Mo steel is widely used in high-temperature components of nuclear and fossil power plants. Accurate modelling of its cyclic behavior over a wide temperature range is essential for structure integrity assessment. In this study, a Chaboche-type constitutive model is employed to describe the cyclic response of 2.25Cr–1Mo steel under various strain amplitudes and temperatures. The isotropic hardening parameter , defined as the difference between the initial and the stabilized peak stresses, plays a key role in characterizing cyclic softening. To capture the coupled dependence of on strain amplitude and temperature, a physics-constrained neural network was developed. The approach incorporates experimental scatter into the calibration process. The predicted parameters are expressed as logarithmic functions of temperature, enabling smooth interpolation and direct implementation in finite element simulations. The proposed model reproduces the experimental cyclic softening behavior with good accuracy. This framework provides a practical and reliable tool for fatigue and inelastic analysis of high-temperature structural components.
{"title":"Neural network-aided constitutive modeling of cyclic softening in 2.25Cr–1Mo steel across temperatures and strain amplitudes","authors":"Fuhai Gao , Cheng Li , Rou Du , Jianguo Gong , Xiaoming Liu , Fuzhen Xuan","doi":"10.1016/j.ijpvp.2025.105738","DOIUrl":"10.1016/j.ijpvp.2025.105738","url":null,"abstract":"<div><div>2.25Cr–1Mo steel is widely used in high-temperature components of nuclear and fossil power plants. Accurate modelling of its cyclic behavior over a wide temperature range is essential for structure integrity assessment. In this study, a Chaboche-type constitutive model is employed to describe the cyclic response of 2.25Cr–1Mo steel under various strain amplitudes and temperatures. The isotropic hardening parameter <span><math><mrow><mi>Q</mi></mrow></math></span>, defined as the difference between the initial and the stabilized peak stresses, plays a key role in characterizing cyclic softening. To capture the coupled dependence of <span><math><mrow><mi>Q</mi></mrow></math></span> on strain amplitude and temperature, a physics-constrained neural network was developed. The approach incorporates experimental scatter into the calibration process. The predicted parameters are expressed as logarithmic functions of temperature, enabling smooth interpolation and direct implementation in finite element simulations. The proposed model reproduces the experimental cyclic softening behavior with good accuracy. This framework provides a practical and reliable tool for fatigue and inelastic analysis of high-temperature structural components.</div></div>","PeriodicalId":54946,"journal":{"name":"International Journal of Pressure Vessels and Piping","volume":"221 ","pages":"Article 105738"},"PeriodicalIF":3.5,"publicationDate":"2025-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145928149","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ultrasonic guided wave-based pipeline defect detection is crucial for achieving efficient and cost-effective structural health monitoring of pipelines. However, signal attenuation and noise interference during wave propagation severely hinder the accurate identification of defect signals. To address this challenge, a Time-Frequency Attention Network (TFA_Net) is proposed, integrating time-frequency domain signal processing with deep learning techniques to improve defect recognition accuracy and enhance noise robustness in ultrasonic guided wave signals. First, the Ultrasonic Guided Wave Defect Dataset (UGW-Dataset) was established, including experimental and simulated data, covering cracks and corrosion defects of various sizes and shapes. Next, a time-frequency attention block (TFA_Block) was designed in TFA_Net to perform multi-scale feature extraction in both time and frequency domains, enabling effective capture of global and local characteristics of defect signals. Experimental results demonstrate that TFA_Net achieves a defect recognition accuracy of 99.4 % on the UGW-Dataset, confirming its exceptional feature extraction and defect recognition capabilities. Furthermore, TFA_Block significantly enhances the robustness of TFA_Net within the signal-to-noise ratio (SNR) range from 40 dB to 10 dB, effectively mitigating the negative impact of noise on recognition accuracy. This study provides an efficient and noise-resilient approach for defect recognition in pipeline structural health monitoring (SHM).
{"title":"TFA_Net: A time-frequency attention network for enhancing defect recognition and noise robustness in ultrasonic guided wave pipeline inspection","authors":"Yunliang Zhao , Donglin Tang , Chao Ding , Heng Cheng","doi":"10.1016/j.ijpvp.2025.105735","DOIUrl":"10.1016/j.ijpvp.2025.105735","url":null,"abstract":"<div><div>Ultrasonic guided wave-based pipeline defect detection is crucial for achieving efficient and cost-effective structural health monitoring of pipelines. However, signal attenuation and noise interference during wave propagation severely hinder the accurate identification of defect signals. To address this challenge, a Time-Frequency Attention Network (TFA_Net) is proposed, integrating time-frequency domain signal processing with deep learning techniques to improve defect recognition accuracy and enhance noise robustness in ultrasonic guided wave signals. First, the Ultrasonic Guided Wave Defect Dataset (UGW-Dataset) was established, including experimental and simulated data, covering cracks and corrosion defects of various sizes and shapes. Next, a time-frequency attention block (TFA_Block) was designed in TFA_Net to perform multi-scale feature extraction in both time and frequency domains, enabling effective capture of global and local characteristics of defect signals. Experimental results demonstrate that TFA_Net achieves a defect recognition accuracy of 99.4 % on the UGW-Dataset, confirming its exceptional feature extraction and defect recognition capabilities. Furthermore, TFA_Block significantly enhances the robustness of TFA_Net within the signal-to-noise ratio (SNR) range from 40 dB to 10 dB, effectively mitigating the negative impact of noise on recognition accuracy. This study provides an efficient and noise-resilient approach for defect recognition in pipeline structural health monitoring (SHM).</div></div>","PeriodicalId":54946,"journal":{"name":"International Journal of Pressure Vessels and Piping","volume":"220 ","pages":"Article 105735"},"PeriodicalIF":3.5,"publicationDate":"2025-12-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145883893","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-25DOI: 10.1016/j.ijpvp.2025.105737
Abdul Rahman Shaik , V. Karthik , Aishwary Vardhan Pandey , R. Divakar
The deformation behaviour of a small punch (SP) test specimen with a longitudinal notch is investigated using finite element (FE) simulations and three-dimensional digital image correlation (3D-DIC) technique. The sensitivity of the SP test to notch geometry such as notch depth, width, and tip radius with regard to the force–deflection response and stress triaxiality are assessed through FE simulations. The integration of stereo-DIC with the SP test setup enabled real-time tracking of notch mouth opening displacement (δSPT) via a virtual extensometer. Through FE simulation and experiments, the trends of δSPT for different ductile materials such as 316LN stainless steel, Modified 9Cr-1Mo steel, and Fe-3.5Ni steel indicated that maximum δSPT consistently occurred at a radial distance of 0.61–0.62 mm from the specimen center. The crack initiation site was confirmed, via scanning electron microscopy examination of deformed specimens from interrupted tests, to occur at the same radial location. A linear correlation was established between δSPT at the onset of plastic instability and the crack tip opening displacement δIc derived from standard single-edge notched bend tests. Notched SP specimens, when combined with DIC and supported by FE modeling, can effectively characterize fracture initiation behaviour. However, the differences in stress state, notch sharpness, and crack driving force must be carefully considered for accurate correlation with standard fracture toughness parameters and reliable application across different material systems.
{"title":"Fracture toughness estimation from notched small punch test using 3D-DIC","authors":"Abdul Rahman Shaik , V. Karthik , Aishwary Vardhan Pandey , R. Divakar","doi":"10.1016/j.ijpvp.2025.105737","DOIUrl":"10.1016/j.ijpvp.2025.105737","url":null,"abstract":"<div><div>The deformation behaviour of a small punch (SP) test specimen with a longitudinal notch is investigated using finite element (FE) simulations and three-dimensional digital image correlation (3D-DIC) technique. The sensitivity of the SP test to notch geometry such as notch depth, width, and tip radius with regard to the force–deflection response and stress triaxiality are assessed through FE simulations. The integration of stereo-DIC with the SP test setup enabled real-time tracking of notch mouth opening displacement (δ<sub>SPT</sub>) via a virtual extensometer. Through FE simulation and experiments, the trends of δ<sub>SPT</sub> for different ductile materials such as 316LN stainless steel, Modified 9Cr-1Mo steel, and Fe-3.5Ni steel indicated that maximum δ<sub>SPT</sub> consistently occurred at a radial distance of 0.61–0.62 mm from the specimen center. The crack initiation site was confirmed, via scanning electron microscopy examination of deformed specimens from interrupted tests, to occur at the same radial location. A linear correlation was established between δ<sub>SPT</sub> at the onset of plastic instability and the crack tip opening displacement δ<sub>Ic</sub> derived from standard single-edge notched bend tests. Notched SP specimens, when combined with DIC and supported by FE modeling, can effectively characterize fracture initiation behaviour. However, the differences in stress state, notch sharpness, and crack driving force must be carefully considered for accurate correlation with standard fracture toughness parameters and reliable application across different material systems.</div></div>","PeriodicalId":54946,"journal":{"name":"International Journal of Pressure Vessels and Piping","volume":"220 ","pages":"Article 105737"},"PeriodicalIF":3.5,"publicationDate":"2025-12-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145883895","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This research work investigates the dissimilar Gas Metal Arc welding (GMAW) of Inconel 718 (IN718) and austenitic stainless steel (ASS304L), utilizing Ni-based filler materials (FMs) ERNiCrCoMo-1 and ERNiCr-3. The dissimilar welds were evaluated for microstructural and mechanical properties performance for high-temperature service conditions. Optical microscopy reveals a partially melted zone (PMZ) and an unmixed zone (UZ) at the weld interfaces, along with the evolution of columnar, cellular, and equiaxed dendritic structures within the weld metals (WMs). The WMs indicate the micro segregation of the weld metal (WM) alloying elements in the form of secondary phases. Scanning Electron Microscope (SEM) equipped with Energy-Dispersive Spectroscopy (EDS) analysis of the weld precipitates indicated that they were enriched in Cr, Mo, and Co-rich carbide phases, which were present in the ERNiCrCoMo-1 WM. Whereas ERNiCr-3 experiences the occurrence of NbC, Ti (C, N), and Cr23C6 phases along the interdendritic spaces. Electron Backscatter Diffraction (EBSD) results highlight the coarse weld microstructures of ERNiCr-3 WM than the ERNiCrCoMo-1 WM. The weld metal microstructures exhibit an improvement in crystallographic texture than the HAZ and base materials (BMs) analysed by inverse pole figures (IPF) and pole figures (PF) maps. The Vickers microhardness of ERNiCrCoMo-1 WM, compared to ERNiCr-3 WM. Room-temperature tensile testing revealed superior performance of ERNiCrCoMo-1 welds (UTS: 690 MPa) over ERNiCr-3 (UTS: 640 MPa). Fractographic SEM indicated ductile fracture for ERNiCrCoMo-1 (failure at ASS304L BM), while ERNiCr-3 failed within the WM, showing mixed-mode features and interdendritic NbC-induced brittleness. At ambient temperature, Charpy impact testing indicated significantly higher toughness in the ERNiCr-3 weld than in the ERNiCrCoMo-1 weld, with both exceeding the 47 J threshold per EN ISO 3580:2017. The impact specimens showed fine dimples and ductile features at the heat-affected zones, with relatively brittle fracture features at the weld center.
{"title":"Dissimilar gas metal arc welding (GMAW) of Inconel 718 and 304L stainless steel: a comparative study of ERNiCrCoMo-1 and ERNiCr-3 filler metals","authors":"Niraj Kumar , Prakash Kumar , Dariusz Fydrych , Chandan Pandey","doi":"10.1016/j.ijpvp.2025.105732","DOIUrl":"10.1016/j.ijpvp.2025.105732","url":null,"abstract":"<div><div>This research work investigates the dissimilar Gas Metal Arc welding (GMAW) of Inconel 718 (IN718) and austenitic stainless steel (ASS304L), utilizing Ni-based filler materials (FMs) ERNiCrCoMo-1 and ERNiCr-3. The dissimilar welds were evaluated for microstructural and mechanical properties performance for high-temperature service conditions. Optical microscopy reveals a partially melted zone (PMZ) and an unmixed zone (UZ) at the weld interfaces, along with the evolution of columnar, cellular, and equiaxed dendritic structures within the weld metals (WMs). The WMs indicate the micro segregation of the weld metal (WM) alloying elements in the form of secondary phases. Scanning Electron Microscope (SEM) equipped with Energy-Dispersive Spectroscopy (EDS) analysis of the weld precipitates indicated that they were enriched in Cr, Mo, and Co-rich carbide phases, which were present in the ERNiCrCoMo-1 WM. Whereas ERNiCr-3 experiences the occurrence of NbC, Ti (C, N), and Cr<sub>23</sub>C<sub>6</sub> phases along the interdendritic spaces. Electron Backscatter Diffraction (EBSD) results highlight the coarse weld microstructures of ERNiCr-3 WM than the ERNiCrCoMo-1 WM. The weld metal microstructures exhibit an improvement in crystallographic texture than the HAZ and base materials (BMs) analysed by inverse pole figures (IPF) and pole figures (PF) maps. The Vickers microhardness of ERNiCrCoMo-1 WM, compared to ERNiCr-3 WM. Room-temperature tensile testing revealed superior performance of ERNiCrCoMo-1 welds (UTS: 690 MPa) over ERNiCr-3 (UTS: 640 MPa). Fractographic SEM indicated ductile fracture for ERNiCrCoMo-1 (failure at ASS304L BM), while ERNiCr-3 failed within the WM, showing mixed-mode features and interdendritic NbC-induced brittleness. At ambient temperature, Charpy impact testing indicated significantly higher toughness in the ERNiCr-3 weld than in the ERNiCrCoMo-1 weld, with both exceeding the 47 J threshold per EN ISO 3580:2017. The impact specimens showed fine dimples and ductile features at the heat-affected zones, with relatively brittle fracture features at the weld center.</div></div>","PeriodicalId":54946,"journal":{"name":"International Journal of Pressure Vessels and Piping","volume":"220 ","pages":"Article 105732"},"PeriodicalIF":3.5,"publicationDate":"2025-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145840274","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-20DOI: 10.1016/j.ijpvp.2025.105708
Wanying Liu , Zeyang Lin , Xinyu Zhu , Yu Lu , Zhi Zhang , Yongbo Yan , Zuoyuan Fan , Yusi Zhu
The corrosion-induced perforation of a 20# steel elbow in a natural gas pipeline was investigated by systematic failure analysis. Experimental methods included macro- and micro-examination, chemical and mechanical testing, microstructural characterization, and corrosion products analysis including EDS/XRD/XPS along with electrochemical measurements. Results indicate that Si and C equivalents do not meet the requirements of GB/T 9711–2017. The elbow material has the characteristics of high strength and low toughness. Microscopic organization inhomogeneity and non-metallic inclusion (Al2O3/SiO2) enrichment phenomenon existed in the perforation area. That induced the microelectrochemical corrosion. Loose corrosion products were FeCO3, Fe3O4 and FeOOH. Under the synergistic effect of CO2, Cl− invasion and sand particle scouring, the corrosion initiated from the inner wall of the elbow and extended stepwise to outside, which eventually led to perforation of the pipe wall. The failure is ascribed to the pitting perforation caused by the synergistic effect of material defects, corrosive medium and mechanical factors. The corrosion mechanism is the interaction of electrochemical corrosion and impingement corrosion.
{"title":"Root cause analysis of corrosion-induced perforation in a natural gas pipeline elbow","authors":"Wanying Liu , Zeyang Lin , Xinyu Zhu , Yu Lu , Zhi Zhang , Yongbo Yan , Zuoyuan Fan , Yusi Zhu","doi":"10.1016/j.ijpvp.2025.105708","DOIUrl":"10.1016/j.ijpvp.2025.105708","url":null,"abstract":"<div><div>The corrosion-induced perforation of a 20# steel elbow in a natural gas pipeline was investigated by systematic failure analysis. Experimental methods included macro- and micro-examination, chemical and mechanical testing, microstructural characterization, and corrosion products analysis including EDS/XRD/XPS along with electrochemical measurements. Results indicate that Si and C equivalents do not meet the requirements of GB/T 9711–2017. The elbow material has the characteristics of high strength and low toughness. Microscopic organization inhomogeneity and non-metallic inclusion (Al<sub>2</sub>O<sub>3</sub>/SiO<sub>2</sub>) enrichment phenomenon existed in the perforation area. That induced the microelectrochemical corrosion. Loose corrosion products were FeCO<sub>3</sub>, Fe<sub>3</sub>O<sub>4</sub> and FeOOH. Under the synergistic effect of CO<sub>2</sub>, Cl<sup>−</sup> invasion and sand particle scouring, the corrosion initiated from the inner wall of the elbow and extended stepwise to outside, which eventually led to perforation of the pipe wall. The failure is ascribed to the pitting perforation caused by the synergistic effect of material defects, corrosive medium and mechanical factors. The corrosion mechanism is the interaction of electrochemical corrosion and impingement corrosion.</div></div>","PeriodicalId":54946,"journal":{"name":"International Journal of Pressure Vessels and Piping","volume":"220 ","pages":"Article 105708"},"PeriodicalIF":3.5,"publicationDate":"2025-12-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145840355","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-19DOI: 10.1016/j.ijpvp.2025.105736
Yuxuan Wu, Cuixiang Pei, Zhenmao Chen
Ultrasonic total focusing imaging method (TFM) with using full matrix capture (FMC) has been widely used for high-resolution imaging of internal flaws in metal structures. However, the detection ability of the ultrasonic TFM for deep and small flaw in thick structures is limited, due to the limited signal energy with a single excitation element in each testing. In this paper, an enhanced ultrasonic TFM with pulse compression and phase coherence is proposed for small flaw inspection in thick-walled structures. Numerical simulations are performed to validate the feasibility of combining pulse compression and phase coherence to enhance the performance of TFM. Furthermore, an enhanced ultrasonic TFM testing system is developed. Experimental results demonstrate that the both the SNR and detecting sensitivity for small flaws in thick-walled structures are significantly improved with the proposed method.
{"title":"An enhanced ultrasonic total focusing method combining pulse compression and phase coherence for thick-walled metal structures","authors":"Yuxuan Wu, Cuixiang Pei, Zhenmao Chen","doi":"10.1016/j.ijpvp.2025.105736","DOIUrl":"10.1016/j.ijpvp.2025.105736","url":null,"abstract":"<div><div>Ultrasonic total focusing imaging method (TFM) with using full matrix capture (FMC) has been widely used for high-resolution imaging of internal flaws in metal structures. However, the detection ability of the ultrasonic TFM for deep and small flaw in thick structures is limited, due to the limited signal energy with a single excitation element in each testing. In this paper, an enhanced ultrasonic TFM with pulse compression and phase coherence is proposed for small flaw inspection in thick-walled structures. Numerical simulations are performed to validate the feasibility of combining pulse compression and phase coherence to enhance the performance of TFM. Furthermore, an enhanced ultrasonic TFM testing system is developed. Experimental results demonstrate that the both the SNR and detecting sensitivity for small flaws in thick-walled structures are significantly improved with the proposed method.</div></div>","PeriodicalId":54946,"journal":{"name":"International Journal of Pressure Vessels and Piping","volume":"220 ","pages":"Article 105736"},"PeriodicalIF":3.5,"publicationDate":"2025-12-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145883894","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-19DOI: 10.1016/j.ijpvp.2025.105733
Wenhui Liu , Chenkai Xu , Honghui Chen , You Zhang
This study investigates the electrochemical corrosion behavior of X80 pipeline steel immersed in soil leachates from Hami and Yingtan regions. The corrosion behavior of X80 steel in alkaline (Hami) and acidic (Yingtan) soil leachates was evaluated by electrochemical tests (Polarization and WBE), surface analysis (SEM/EDS, XRD) and SKP mapping. Results indicate Hami soil's alkaline leachate promotes protective films and iron oxide/hydroxide formation, while Yingtan soil's acidic leachate induces hydrogen evolution corrosion. Hami-exposed samples show substantial corrosion product accumulation in 7 days. The heat-affected zone (HAZ) initially exhibits the highest corrosion tendency, decreasing with time, contrasting with accelerated corrosion in the base metal (BM) and intermediate response in weld metal (WM). This study offers insights into X80 pipeline steel's corrosion mechanisms in different soils, emphasizing local soil conditions' crucial role in corrosion behavior.
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Pub Date : 2025-12-16DOI: 10.1016/j.ijpvp.2025.105731
Yukun Li , Shuang Zhao , Lu Jiang , Yi Li , Xinlei Wu , Siyuan Ren , Baipeng Ding , Buyun Huang
X80 pipeline steel is widely used in long-distance oil and gas transportation due to its high strength and toughness. However, reducing wall thickness to cut costs can lead to stress concentration during forming and under external loads. Since stress can significantly alter the magnetic properties of ferromagnetic materials, magnetic characterization techniques provide a promising approach for stress evaluation; Nevertheless, variations in magnetic parameters caused by plastic strain introduce challenges in accurate stress assessment. In this study, we performed a series of uniaxial tension tests to introduce different levels of plastic strain and identified two hardening stages: an internal stress-dominated stage and a dislocation density-dominated stage. Corresponding models were used to describe their influence on magnetic behavior. Based on the energy minimization principle, the relationship between coercivity and stress under uniaxial loading was derived. A magneto-mechanical behavior model for the elastoplastic stage was then established by incorporating the effect of internal stress and dislocation density. The coercivity variation under combined elastic-plastic deformation was subsequently analyzed. Theoretical predictions show good agreement with experimental results, and a representative example was presented to demonstrate the model's applicability in engineering contexts.
{"title":"A magneto-mechanical model for X80 pipeline steel considering elastoplastic deformation","authors":"Yukun Li , Shuang Zhao , Lu Jiang , Yi Li , Xinlei Wu , Siyuan Ren , Baipeng Ding , Buyun Huang","doi":"10.1016/j.ijpvp.2025.105731","DOIUrl":"10.1016/j.ijpvp.2025.105731","url":null,"abstract":"<div><div>X80 pipeline steel is widely used in long-distance oil and gas transportation due to its high strength and toughness. However, reducing wall thickness to cut costs can lead to stress concentration during forming and under external loads. Since stress can significantly alter the magnetic properties of ferromagnetic materials, magnetic characterization techniques provide a promising approach for stress evaluation; Nevertheless, variations in magnetic parameters caused by plastic strain introduce challenges in accurate stress assessment. In this study, we performed a series of uniaxial tension tests to introduce different levels of plastic strain and identified two hardening stages: an internal stress-dominated stage and a dislocation density-dominated stage. Corresponding models were used to describe their influence on magnetic behavior. Based on the energy minimization principle, the relationship between coercivity and stress under uniaxial loading was derived. A magneto-mechanical behavior model for the elastoplastic stage was then established by incorporating the effect of internal stress and dislocation density. The coercivity variation under combined elastic-plastic deformation was subsequently analyzed. Theoretical predictions show good agreement with experimental results, and a representative example was presented to demonstrate the model's applicability in engineering contexts.</div></div>","PeriodicalId":54946,"journal":{"name":"International Journal of Pressure Vessels and Piping","volume":"220 ","pages":"Article 105731"},"PeriodicalIF":3.5,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145790325","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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