Addressing Hydrogen Embrittlement in the SAE J2579 Fuel Cell Vehicle Tank Standard

Addressing Hydrogen Embrittlement in the SAE J2579 Fuel Cell Vehicle Tank

Standard

Brian SomerdaySandia National Laboratories

Livermore, CA, USA

Christine SloaneSloaneSolutions, LLC

Kewadin, MI, USA

International Conference on Hydrogen Safety ICHS 2011San Francisco, CA, USA

September 14, 2011

Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy under contract DE-AC04-94AL85000

SAE J2579 focuses on safety qualification of vessel in Compressed Hydrogen Storage

System of FCVs

•Compressed Hydrogen Storage System (CHSS) boundary defined by interfaces that isolate stored high pressure H2

•All containment vessel designs include metal components (e.g., composite vessels have boss and liner)

ContainmentVessel

ContainerIsolation

Valve

FillCheckValve

ExcessflowReceptacle

with check

Full SystemIsolation

LowPressure

Regulator

PRVPRV

HighPressure

Regulator

Hydrogen Fuel Handling System

Compressed HydrogenStorage System

PRD

ServiceDefuel Shufoff

vent

ContainmentVessel

ContainerIsolation

Valve

FillCheckValve

ExcessflowReceptacle

with check

Full SystemIsolation

LowPressure

Regulator

PRVPRV

HighPressure

Regulator

Hydrogen Fuel Handling System

Compressed HydrogenStorage System

PRD

ServiceDefuel Shufoff

vent

Barthélémy, 1st ESSHS, 2006

a

Number of pressure cycles, N

crack in H2

crack in N2

Safety qualification of vessel must consider hydrogen embrittlement of metal

componentsHydrogen embrittlement accelerates fatigue cracking

Nf = Ninitiation + Ngrowth

H2

H2

H2

H2

p

a

H2

H2

H2

Vessel safety qualification typically conducted by either engineering analysis or performance

testing

•Design qualification in SAE standards based on performance testing

p

Ri

Ro

at

stress analysis: K = p[f(a, t ,Ro, Ri)]

crack growth law: da/dN = C(K)m

engineeringanalysis

pressure

p


performancetesting

Nf

Vessel safety qualification in SAE J2579 is based on performance

testing

•These performance tests do not evaluate “durability” under H2 gas pressure cycling, i.e., hydrogen embrittlement

Pneumatic test (H2) Hydraulic test

Durability Performance Verification Test

cb

Proo

f Pr

essu

re

5% cy -40Ca

5% cy +50Cb

40%cy 15-25Cc

150%NWP

+55oC +55oC a

Pres

sure

time

BurstBP0 <20%

Leak

/ P

erm

eatio

n>

30 h

rs

a Fuel/defuel cycles @-40oC with initial system equilibration @ -40oC, 5 cycles with +20oC fuel; 5 cycles with <-35oC fuelb Fuel/defuel cycles @+50oC with initial system equilibration @+50oC, 5 cycles with <-35oC fuelc Fuel/defuel cycles @15-25oC with service (maintenance) defuel rate, 50 cycles

5% cy +50C5% cy -40C40%cy 15-25C

Leak

/ P

erm

eatio

n>

30 h

rs

180%NWP

125%NWP115%NWP80%NWP

ab

Expected-Service Performance Verification Test

500 cy = light duty1000 cy = heavy duty

cb

Proo

f Pr

essu

re

5% cy -40Ca

5% cy +50Cb

40%cy 15-25Cc

150%NWP

+55oC +55oC a

Pres

sure

time

BurstBP0 <20%

Leak

/ P

erm

eatio

n>

30 h

rs

a Fuel/defuel cycles @-40oC with initial system equilibration @ -40oC, 5 cycles with +20oC fuel; 5 cycles with <-35oC fuelb Fuel/defuel cycles @+50oC with initial system equilibration @+50oC, 5 cycles with <-35oC fuelc Fuel/defuel cycles @15-25oC with service (maintenance) defuel rate, 50 cycles

5% cy +50C5% cy -40C40%cy 15-25C

Leak

/ P

erm

eatio

n>

30 h

rs

180%NWP

125%NWP115%NWP80%NWP

ab

Expected-Service Performance Verification Test

500 cy = light duty1000 cy = heavy duty

Pres

sure

Dam

age

Dro

p

time

BP0 <20%

ResidualStrength

Chem

ical

s

48 hr

N cycles15C-25C

chemicalexposure 150% NWP

burst

125%NWP

180%NWP

1000 hr+85oC

M cycles-40oC

M cycles+85oC, 95%RH

10cycles

15-25oCProo

f Pre

ssur

e

80%NWP

N cycles•3500 cycles passenger light-duty• 7000 cycles commercial, heavy-dutyM cycles• 1000 cycles passenger light-duty• 2000 cycles commercial, heavy-duty

Pres

sure

Dam

age

Dro

p

time

BP0 <20%

ResidualStrength

Chem

ical

s

48 hr

N cycles15C-25C

chemicalexposure 150% NWP

burst

125%NWP

180%NWP

1000 hr+85oC

M cycles-40oC

M cycles+85oC, 95%RH

10cycles

15-25oCProo

f Pre

ssur

e

80%NWP

N cycles•3500 cycles passenger light-duty• 7000 cycles commercial, heavy-dutyM cycles• 1000 cycles passenger light-duty• 2000 cycles commercial, heavy-duty

Logic flow for addressing hydrogen embrittlement through performance testing in

SAE J2579

•Recent activity focused on Appendix C.14 and Appendix C.15

Metals in vessel are 6061 Al or high-nickel 316 stainless steel?(SAE J2579 Appendix B.2.3)

Metals in vessel meet acceptance criteria from materials testing in H2?(SAE J2579 Appendix C.15)

Vessel qualified using existing expected-service (pneumatic) and durability (hydraulic) performance tests (SAE J2579 Section 5.2.2)

YES NO

Vessel qualified using existing performance tests (SAE J2579 Section 5.2.2) AND new (more extreme) H2 gas cycling test (SAE J2579 Appendix C.14)

NO

YES


SAE J2579

•Tests in Appendix C.15 determine whether material has unrestricted (i.e., not design specific) hydrogen compatibility




YES NO


NO

YES

Appendix C.15 materials test:slow strain rate tensile test

HH

HH

HH

H2

H2H2

H2

H2 H2

OR

•Issues addressed:–Acceptance criterion established as RAH2/RAair > 0.7

–Test conducted in H2 gas or with “precharged” H

–Test temperature(s)

RA

Appendix C.15 materials test:fatigue crack initiation test

stress (S)

cycles to failure (Nf ~ Ninitiation)

• Issues addressed:–R ratio, i.e., ratio of Smin to Smax

–Stress-cycle frequency (f)


–Acceptance criterion, e.g., Nf(H2)/Nf(air) ~ 1air

H2

Appendix C.15 materials test:“long crack” growth test

da/dN

K

H2

H2

H2

H2H2

H2

H2H

HH

load

aH2

H2

H2

H2H2

H2

H2H

HH

load

a

air

H2

• Issues addressed:–Load-cycle frequency


–Acceptance criterion?

Load-cycle frequency must be specified for fatigue tests conducted in H2 gas

Magnitude of accelerated fatigue cracking in H2 gas depends on load-cycle frequency

A.H. Priest, British Steel, 1983


SAE J2579

•Performance test in Appendix C.14 evaluates design-specific hydrogen compatibility




YES NO


NO

YES

Performance test in Appendix C.14 intended to account for H2-accelerated fatigue

cracking

• Issues addressed:–Pressure-cycle profile

–Test temperature

–Number of cyclesH2 pressure


125% NWP

rise time > 5 min hold time > 2 min

p

H2

H2

H2

H2

H2

H2H2

fillermaterial a

2 MPa

SAE working group on hydrogen embrittlement represents international

effort

• SAE J2579 Appendix B.2.3• SAE J2579 Appendix C.15• SAE J2579 Appendix C.14

JapanJARIAIST/HYDROGENIUS

EuropeAdam OpelBMWRobert BoschLinde

USAGMSandia National Laboratories

Summary

•Vehicle tank standard SAE J2579 describes safety qualification for Compressed Hydrogen Storage System

•Safety qualification based on performance testing–Hydraulic long-term durability test does not account for

hydrogen embrittlement

•New tests developed for SAE J2579 to evaluate hydrogen compatibility of vessel designs–Material-level testing determines whether material has

unrestricted (i.e., not design specific) hydrogen compatibility

–Component-level testing evaluates design-specific hydrogen compatibility

Addressing Hydrogen Embrittlement in the SAE J2579 Fuel Cell Vehicle Tank Standard

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