Multi-scale approach to hydrogen susceptibility based on pipe-forming deformation history

Hydrogen-induced-cracking initiates without external loading due to residual stresses. Pipe manufacturing process composed of crimping, $U$-ing, $O$-ing, and expansion has a major impact on local hydrogen concentration, as strain pattern evolves from one forming step to another, causing residual stresses that serve as driving force for hydrogen diffusion. The novelty of the presented work lies in the development of a multi-scale approach that links the residual stresses from the macroscopic pipe-forming process with locally dissolved hydrogen atoms in microstructure under the consideration of microstructural heterogeneities to identify areas susceptible to hydrogen-induced-cracking. First, a 3d-pipe-forming-model was built. Second, representative volume elements with lattice defects were generated to analyze hydrogen trapping in microstructure. Third, representative volume elements were placed in the pipe via sub-modeling, so that local loading history of the pipe was assigned to microstructure models. At the end of the pipe-forming process, representative volume elements were loaded with hydrogen on the surface and final hydrogen concentration was simulated based on residual stresses, considering microstructural effects such as grain size/shape, crystallographic texture and hydrogen traps, e.g. dislocations, voids and inclusions. On meso-/macroscale, a combined isotropic–kinematic hardening material model was implemented, while on microscale, a phenomenological crystal-plasticity-hydrogen-diffusion model was coded. According to the multi-scale simulations under the consideration of microstructural effects the bottom center position in the pipe was detected to be critical to hydrogen-induced-cracking as the maximum local hydrogen concentration was predicted at that location. Based on the loading history hydrogen-induced-cracking susceptibility increases from voids to hard and soft non-metallic inclusions.