As a clean energy utilization device, full cell is gaining more and more attention. Proton exchange membrane (PEM) is a key component of the full cell. The commercial-sulfonated, tetrafluoroethylene-based fluoropolymer-copolymer (Nafion) membrane exhibits excellent proton conductivity under a fully humidified environment. However, it also has some disadvantages in practice, such as high fuel permeability, a complex synthesis process, and high cost. To overcome these disadvantages, a low-cost and novel membrane was developed. The sulfonated poly (ether ether ketone) (SPEEK) was selected as the base material of the proton exchange membrane. Sulfonated graphene (SG) was cross-linked with SPEEK through the elimination reaction of hydrogen bonds. It was found that the sulfonic acid groups and hydrophilic oxygen groups increased obviously in the resultant membrane. Compared with the pure SPEEK membrane, the SG-reinforced membrane exhibited better proton conductivity and methanol permeability prevention. The results indicate that the SG/SPEEK could be applied as a new proton exchange membrane in fuel cells.

The process optimization and structural safety improvement of the in-service repair welding of the X80 pipeline are very important. In this paper, the temperature, microstructure, and stress distribution were analyzed using the combination of TMM (thermal-metallurgical-mechanical) simulations and the corresponding verification experiments. The effects of the sleeve material strength and the fillet weld size were discussed. The results showed that the fillet weld zone was mainly composed of ferrite and bainite when the material of the sleeve pipe was Q345B. Furthermore, the sleeve pipe’s HAZ (heat affected zone) was dominated by lath martensite, lath bainite, and granular bainite. Moreover, granular bainite and a small amount of ferrite were found in the HAZ of the X80 pipe. It was found that, as the fillet weld size increased, the welding residual stress distribution became more uniform. The hoop stress at weld toe reduced from ~860 MPa of case A to ~680 MPa of case E, and the axial stress at weld toe reduced from ~440 MPa of case A to ~380 MPa of case E. From the viewpoint of welding residual stress, fillet weld size was suggested to be larger than 1.4T. The stress concentration and the stress distribution showed a correlation with the cracking behavior. Weld re-solidification ripples on the weld surface and weld ripples between welding passes or near the weld toe could cause stress concentration and the corresponding crack initiation. Furthermore, when the material of the sleeve pipe changed from Q345B to X80, the high-level tensile stress zone was found to be enlarged. The hoop stress at weld toe increased from ~750 to ~800 MPa, and the axial stress at weld toe increased from ~500 to ~600 MPa. After implementing the new sleeve repair welding process where X80 replaces the material of sleeve pipe, the cracking risk in sleeve pipe will improve. From the perspective of the welding residual stress, it was concluded that the fillet weld size reduction and the sleeve material strength improvement are harmful to in-service welded structures’ safety and integrity.

Low-temperature embrittlement in the heat-affected zone (HAZ) of heavy-wall X80 weld joints is a primary challenge for arctic oil & gas exploitation. In this paper, the influence of intercritically reheated coarse-grained HAZ (ICCGHAZ) on the low-temperature toughness of the weld joint in a 22 mm thick X80 spiral submerged arc welded pipe was studied through instrumented Charpy V-notch impact test at −80~20 °C and corresponding fracture surface characterization. The results indicated that the influence of ICCGHAZ on the overall toughness of the weld joint is related to temperature. At temperatures below −45 °C, individual and tiny martensite-austenite (MA) constituent debonding can trigger cleavage fracture–which was proved to be nucleation-controlled–and the probability of embrittlement of the ICCGHAZ increases. At temperatures higher than −45 °C, only relatively large or closely distributed MA constituent in ICCGHAZ satisfies the conditions to trigger propagation-controlled cleavage fractures, and the influence of ICCGHAZ on the overall toughness is not remarkable.

There remains a lack of systematic understanding of burn-through instability, which also restricts the development of evaluation criteria. Based on the designed test device, the dynamic evolution behavior and failure mechanism of burn-through instability were investigated by combining in-situ CCD observation and failure analysis. In the initial stage of burn-through instability, the penetrating defect initiated beneath the molten pool bulge and propagated toward the arc. Finally, the weld centerline cracks or pinholes contributed to the pipeline failure. Based on in-situ observation, the burn-through pinhole was found to be forming in the overheating zone. Cracks and pinholes were found simultaneously in the burn-through instability zone and played an essential role in the burn-through instability. It could be concluded that a major burn-through hole was mainly developed from the fusion line to the inner wall surface along the wall thickness. According to the failure behavior and phenomena, the in-service burn-through instability area was divided into four parts, which were the damage failure (DF) zone, burn-through instability (BTI) zone, propagation (P) zone, and secondary burn-through zone (BT2). The failure mechanisms of the damage failure (DF) zone and burn-through instability (BTI) zone were significantly affected by the high temperature and plastic strain. The failure behavior of the propagation (P) zone was influenced considerably by the DF and BTI zones. The secondary burn-through zone was mainly affected by the high temperature. The uneven distribution of chemical elements showed an important influence on defect initiation.

We conclude on the governing mechanism of burn-through and identify the area of highest risk for burn-through occurrence due to a specific combination of loading in this area. In order to investigate the mechanism of burn-through during in-service welding, an exploratory study combining both experiments and finite element simulations was presented. Combined with the theory of high-temperature failure, the initial position of burn-through and its mechanism were discussed. The results showed that burn-through was a kind of intergranular brittle rupture happened at the cooling stage of in-service welding. It started from the partially melted zone, and the cracks expanded along the weakened grain boundaries. When the cracks eventually penetrated to the inner wall, burn-through happened.