This paper summarizes a series of the authors’ research in the field of assessing the operational degradation of oil and gas transit pipeline steels. Both mechanical and electrochemical properties of steels are deteriorated after operation, as is their resistance to environmentally-assisted cracking. The characteristics of resistance to brittle fracture and stress corrosion cracking decrease most intensively, which is associated with a development of in-bulk dissipated microdamages of the material. The most sensitive indicators of changes in the material’s state caused by degradation are impact toughness and fracture toughness by the J-integral method. The degradation degree of pipeline steels can also be evaluated nondestructively based on in-service changes in their polarization resistance and potential of the fracture surface. Attention is drawn to hydrogenation of a pipe wall from inside as a result of the electrochemical interaction of pipe metal with condensed moisture, which facilitates operational degradation of steel due to the combined action of operating stresses and hydrogen. The development of microdamages along steel texture was evidenced metallographically as a trend to the selective etching of boundaries between adjacent bands of ferrite and pearlite and fractographically by revealing brittle fracture elements on the fracture surfaces, namely delamination and cleavage, indicating the sites of cohesion weakening between ferrite and pearlite bands. The state of the X52 steel in its initial state and after use for 30 years was assessed based on the numerical simulation method.

The paper discusses the basic issues of the local approach to ductile fracture of structural metals, with particular emphasis on the failure due to microvoid development. The mechanisms of nucleation of voids around inclusions and precipitates are characterized. The criteria for the nucleation of voids resulting from cracking of the existing particles or their separation from the material matrix are presented. Selected results of experimental studies and Finite Element Method (FEM) simulations on nucleation of voids are discussed. The analytical and numerical models of growth and coalescence of voids are described, indicating the effect of the stress state components on the morphology of voids and the course of the cracking on a microscopic scale.

The article presents the application of the acoustic emission (AE) technique for detecting crack initiation and examining the crack growth process in steel used in engineering structures. The tests were carried out on 40CrMo steel specimens with a single edge notch in bending (SENB). In the tests crack opening displacement, force parameter, and potential drop signal were measured. The fracture mechanism under loading was classified as brittle. Accurate AE investigations of the cracking process and SEM observations of the fracture surfaces helped to determine that the cracking process is a more complex phenomenon than the commonly understood brittle fracture. The AE signals showed that the frequency range in the initial stage of crack development and in the further crack growth stages vary. Based on the analysis of parameters and frequencies of AE signals, it was found that the process of apparently brittle fracture begins and ends according to the mechanisms characteristic of ductile crack growth. The work focuses on the comparison of selected parameters of AE signals recorded in the pre-initiation phase and during the growth of brittle fracture cracking.

Tensile uniaxial test is typically used to determine the strength and plasticity of a material. Nominal (engineering) stress-strain relationship is suitable for determining properties when elastic strain dominates (e.g., yield strength, Young’s modulus). For loading conditions where plastic deformation is significant (in front of a crack tip or in a neck), the use of true stress and strain values and the relationship between them are required. Under these conditions, the dependence between the true values of stresses and strains should be treated as a characteristic—a constitutive relationship of the material. This article presents several methodologies to develop a constitutive relationship for S355 steel from tensile test data. The constitutive relationship developed was incorporated into a finite element analysis of the tension test and verified with the measured tensile test data. The method of the constitutive relationship defining takes into account the impact of high plastic strain, the triaxiality stress factor, Lode coefficient, and material weakness due to the formation of microvoids, which leads to obtained correctly results by FEM (finite elements method) calculation. The different variants of constitutive relationships were applied to the FEM loading simulation of the three-point bending SENB (single edge notched bend) specimen to evaluate their applicability to the calculation of mechanical fields in the presence of a crack.

This paper presents results of strength and fracture toughness properties of low-carbon high-strength Hardox-400 steel. Experimental tests were carried out for specimens of different thickness at wide temperature range from −100 to 20 °C. The dependences of the characteristic of material strength and fracture toughness on temperature based on experimental data are shown. Numerical calculation of the stress and strain distributions in area before crack tip using the finite element method (FEM) was done. Based on results of numerical calculation and observation of the fracture surfaces by scanning electron microscope (SEM), the critical local stress level at which brittle fracture takes place was assessed. Consideration of the levels of stress and strain in the analysis of the metal state at the tip of the crack allowed to justify the occurrence of the brittle-to-ductile fracture mechanism. On the basis of the results of stretch zone width measurements and stress components, the values of fracture toughness at the moment of crack initiation were calculated.

This article presents a comprehensive improvement in the experimental analysis of cracking processes in smooth and sharp V-notched samples taken from gas transport pipelines, utilizing the acoustic emission (AE) method. The research aimed to establish a robust correlation between the failure mechanisms of uni-axially tensile samples and the distinct characteristics of AE signals for enhanced quality management in pipeline integrity. The study encompassed materials from two different straight pipe sections, encompassing both long-term used materials and new, unused materials. Through the application of the k-means grouping method to AE signal analysis, we achieved the identification of AE signal parameters characteristic of various stages of the material destruction process. This advancement introduces a significant improvement in monitoring and managing the operational safety of pipeline networks, offering a methodology that leverages advanced acoustic emission signal analysis. The outcomes present significant implications for the pipeline industry by proposing methods to enhance safety systems and more effectively manage the integrity and quality of gas infrastructure.