Abstract

This study investigates hydrogen-assisted fatigue crack growth (FCG) in vintage pipeline steels to quantify grade-dependent degradation under hydrogen–natural gas blending conditions. Fatigue behavior was evaluated using compact-tension specimens extracted from API X52 and X70 pipeline steels and tested in natural gas–hydrogen mixtures at a total pressure of 6.9 MPa and ambient temperature. Hydrogen concentration was systematically varied from 0% to 100% H2 to assess its influence on crack-length evolution, fatigue crack growth rate, and fracture morphology. Crack propagation was characterized as a function of the stress-intensity-factor range, and scanning electron microscopy was used to examine hydrogen-induced changes in fracture mechanisms. The results demonstrate that FCG accelerates as hydrogen concentration increases, with a strong dependence on steel grade. X70 exhibited substantially greater hydrogen-induced FCG acceleration than X52, despite showing better fatigue resistance under hydrogen-free conditions. Fatigue life reductions approached 60% for X70 at 100% hydrogen, compared with approximately 30% for X52 under the same conditions. Significant early-life sensitivity was observed in X70 even at low hydrogen concentrations, whereas X52 showed more pronounced acceleration during later stages of crack growth. The influence of hydrogen was nonlinear and tended to stabilize at elevated blend fractions, indicating a saturation-type response once hydrogen-assisted crack growth became dominant. Fractographic analyses revealed a transition from ductile tearing in natural gas environments to terrace- and facet-controlled crack propagation in hydrogen-rich environments, accompanied by secondary cracking and river-pattern features. These findings demonstrate that hydrogen–natural gas blending can significantly alter fatigue crack growth behavior and relative material performance in pipeline steels, highlighting the need for grade-specific integrity assessment of existing pipeline infrastructure.

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