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Effect of residual stress on sulfide stress cracking and fracture toughness in carbon steel: A phase-field modeling approach
Department of Mechanical and Nuclear Engineering, Khalifa University, Abu Dhabi, 127788, United Arab Emirates.
KTH, School of Engineering Sciences (SCI), Engineering Mechanics. Department of Mechanical and Nuclear Engineering, Khalifa University, Abu Dhabi, 127788, United Arab Emirates; Advanced Digital and Additive Manufacturing Cente, Khalifa University, Abu Dhabi, 127788, United Arab Emirates.ORCID iD: 0000-0002-9438-9648
2025 (English)In: Theoretical and applied fracture mechanics (Print), ISSN 0167-8442, E-ISSN 1872-7638, Vol. 138, article id 104911Article in journal (Refereed) Published
Abstract [en]

The susceptibility of OCTG-grade alloys to sulfide stress cracking (SSC) in hydrogen sulfide (H2S)-rich sour environments poses a unique challenge for downhole oil and gas exploration, particularly when considering the role of residual stresses. These stresses, inherent in materials from fabrication processes, can strongly influence their cracking resistance even in the absence of external loads. This study numerically examines the effect of residual stresses on the fracture toughness (KISSC) measurements associated with SSC resistance of a high-strength low-alloy carbon steel C110 in H2S-containing aqueous test solution using industry-standard single-edge notched tension (SENT) and double-cantilever beam (DCB) testing methodologies. Residual stresses are measured on pipe samples and are incorporated into the finite element model of the pipe through a thermo-mechanical equivalent loading. The residual stress field is then mapped onto the fracture mechanics test specimens to represent the initial stress distributions. A coupled deformation-diffusion phase-field framework is implemented in COMSOL to simulate crack propagation under the combined influence of residual stress and environmental factors. The results offer insights into SSC mechanisms, demonstrating that elevated residual stress levels in both SENT and DCB tests affect SSC initiation thresholds and arrest, signifying reduced fracture toughness and increased susceptibility to SSC. This study underscores the importance of considering residual stresses in fracture-mechanics-based SSC integrity assessments to improve the reliability of components in sour service applications.

Place, publisher, year, edition, pages
Elsevier BV , 2025. Vol. 138, article id 104911
Keywords [en]
Finite element analysis, Fracture toughness, Phase-field, Residual stresses, Sulfide stress cracking
National Category
Applied Mechanics
Identifiers
URN: urn:nbn:se:kth:diva-362051DOI: 10.1016/j.tafmec.2025.104911ISI: 001450603700001Scopus ID: 2-s2.0-105000293396OAI: oai:DiVA.org:kth-362051DiVA, id: diva2:1949724
Note

QC 20250428

Available from: 2025-04-03 Created: 2025-04-03 Last updated: 2025-04-28Bibliographically approved

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Barsoum, Imad

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