Evaluation of Hydrogen Pressure Vessels Using Slow Strain Rate Testing and Fracture Mechanics Analysis

A total of 108 seamless, forged pressure vessels, fabricated from ASTM A372 type IV (UNS K14508) and type V low alloy steel, are currently in 4,200 psi (29 MPa) gaseous hydrogen (GH{sub 2}) service at the Kennedy Space Center`s (KSC) Space Shuttle Launch Complex 39 (LC-39). The vessels were originally used in 6,000 psi (41 MPa) GH{sub 2} service during the Apollo program. NASA recently received a letter of warning from the manufacturer of the vessels stating that the subject vessels should be now be removed from GH{sub 2} service due to the fact that the ultimate tensile strength (UTS) of many of the vessels exceeds the maximum limit of 126 ksi (869 MPa) now imposed on A372 steel intended for GH{sub 2} service, and therefore are susceptible to hydrogen environment embrittlement. Due to the expense associated with vessel replacement, it was decided to determine by testing and analysis whether or not the vessels needed to be removed from GH{sub 2} service. Slow strain rate testing was performed under hydrogen charging conditions to determine the value of the threshold fracture toughness for sustained loading crack growth in GH{sub 2}, (K{sub H}) for the vessel material, this value was then used in a fracture mechanics safe-life analysis (a 20-year service life was modeled) that indicated the vessels are safe for continued use.