Comparing Hydrogen Transport and Trapping Mechanisms: Controlling Embrittlement as a Function of Charging Method in Steels and Nickel Alloys

Many current and next generation energy systems are reliant on the production, transportation, storage and use of gaseous hydrogen, often at high pressure. The safety, durability, performance, and economic operation of such systems are challenged due to the reality that hydrogen promotes a variety of degradation modes in otherwise high performance materials. Such degradation is often manifested as cracking which compromises the structural integrity of metals and polymers; a behaviour complicated by time and operating cycle (e.g., stress, hydrogen pressure, and temperature) dependencies of degradation. As an example, concurrent stressing and hydrogen exposure at typical pressure vessel or pipeline environmental conditions can promote cracking in modern metallic systems at one-tenth the fracture toughness. Such hydrogen-induced degradation phenomena are generally categorised as hydrogen embrittlement. The breadth and importance of hydrogen damage phenomena have not gone unnoticed in the scientific community with an immense amount of work conducted over the past 100 years. The problem is broadly interdisciplinary and such work has involved metallurgy, chemistry, solid mechanics and fracture mechanics, surface science, molecular and atomic hydrogen physics, non-destructive inspection, materials characterisation, and mechanical-properties testing. This important work notwithstanding, major challenges face those tasked with managing complex engineering structures exposed to demanding environment and mechanical loading conditions. The challenge here is to transform debate on mechanisms of hydrogen damage into a focus on quantitative, predictive models of material cracking properties. Overarching these challenges is the inescapable fact that hydrogen damage problems are immensely complex, requiring understanding of time-cycle dependent processes operating at the atomic scale to impact behaviour manifest at the macroscopic scale.
In this study we will attempt to characterise the hydrogen solubility, transport and trapping which govern embrittlement associated with cracking of a range of Steel and Nickel-based alloys as a function of hydrogen charging technique (i.e., gaseous charging vs electrochemical charging). Initial experiments will include hydrogen permeation studies and thermal desorption analysis for hydrogen diffusion and trap character of the above-mentioned alloy systems. Further experimental work could include fracture mechanics / fracture toughness testing as well as analytical electron microscopy.
This research project is funded in part by Element Materials Technology who will also provide co-supervision. Element Materials Technology is a global provider of testing, inspection and certification services to industry, with over 200 laboratories conducting destructive testing and non-destructive testing of metals, composites, polymers, elastomers, and resins to determine their potential properties, performance, strength, durability, and resistance to corrosion. The candidate will also make use of the state-of-the-art testing facilities located within the Henry Royce Institute for Advanced Materials Research and Innovation at the University of Manchester.

The EPSRC Centre for Doctoral Training in Advanced Metallic Systems was established to address the metallurgical skills
gap, highlighted in several reports [1-3] as a threat to the competitiveness of UK industry, by training non-materials
graduates from chemistry, physics and engineering in a multidisciplinary environment. Although we will have supplied ~140
highly capable metallurgical scientists and engineers into industry and academia by the end of our existing programme,
there remains a demonstrable need for doctoral-level training to continue and evolve to meet future industry needs. We
therefore propose to train a further 14 UK based PhD and EngD students per cohort as well as 5 Irish students per
cohort through I-Form.

Manufacturing contributes over 10% of UK GVA with the metals sector contributing 12% of this (£10.7BN [4,5]) and
employing ~230,000 people directly and 750,000 indirectly. It is estimated that ~2300 graduates are required annually to
meet present and future growth [5]. A sizeable portion of these graduates will require metallurgical expertise and current
numbers fall far short. From UK-wide HESA data, we estimate there are ~330 home UG/PGT qualifiers in materials and
~35 home doctoral graduates in metallurgy annually, including existing AMSCDT graduates, so it is unsurprising that
industry continues to report difficulties in recruiting staff with the required specialist metallurgical knowledge and
professional competencies.

As well as addressing this shortfall, the CDT will also impact directly on the companies with which it collaborates, on the
wider high value manufacturing sector and on the UK economy as a whole, as follows:

1. Collaborating companies, across a wide range of businesses in the supply chain including SMEs and research
organisations will benefit directly from the CDT through:

- Targeted projects in direct support of their business and its future development and competitiveness.
- Access to the expertise and facilities of the host institutions.
- Involvement in the training of the next generation of potential employees with advanced technical and leadership skills
who can add value to their organisations.

2. The UK High-Value Manufacturing Community will benefit as the CDT will:

- Develop the underpinning science and advanced-level knowledge base required by future high technology areas, where
there is high expectation of gross added value.
- Provide an enhanced route to exploitation, by covering the full spectrum of technology readiness levels.
- Ensure dissemination of knowledge to the sector, through student-led SME consultancy projects, the National Student
Conference in Metallic Materials and industry events.

3. The wider UK economy will benefit as the CDT will:

- Promote materials science and engineering and encourage future generations to enter the field, through outreach
activities developed by the students that will increase public awareness of the discipline and its contribution to modern
life, and highlight its importance to future innovation and technologies.
- Develop and exploit new technologies and products which will help to maintain a competitive UK advanced
manufacturing sector, ensure an internationally competitive and balanced UK economy for future generations and
contribute to technical challenges in key societal issues such as energy and sustainability.

References:
1. Materials UK Structural Materials Report 2009
2. EPSRC Materials International Review 2008
3. EPSRC Materially Better Call 2013
4. The state of engineering, Engineering UK 2017
5. Vision 2030: The UK Metals Industry's New Strategic Approach, Metals Forum