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Metals
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Failure Analysis and Evaluation of Metallic Materials
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Failure Analysis and Evaluation of Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: 31 July 2026 | Viewed by 1903

Special Issue Editors

Dr. Yi Shuai

E-Mail Website
Guest Editor
College of Safety and Ocean Engineering, China University of Petroleum-Beijing, Beijing 102249, China
Interests: integrity evaluation; failure analysis; detection and monitoring; steel pipes
Dr. Zhanfeng Chen

E-Mail Website
Guest Editor
School of Mechanical Engineering, Hangzhou Dianzi University, Hangzhou 310018, China
Interests: structural integrity assessment; corroded pipeline; submarine pipeline; residual strength; burst pressure
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Integrity assessment of steel pipelines serves as a critical component in ensuring the safe operation of energy transportation systems. With the increasing global energy demand and the large-scale application of emerging energy carriers such as hydrogen, carbon dioxide (CO2), and liquefied natural gas (LNG), steel pipelines are subjected to complex multi-physical loads, including high pressure, corrosion, low-temperature conditions, and hydrogen embrittlement. Structural failures in these systems may lead to catastrophic accidents, resulting in casualties, environmental pollution, and significant economic losses. Through systematic integrity evaluations, potential risks—such as material defects, dent deformations, corrosion damage, and welding weak zones—can be accurately identified. By integrating online monitoring, non-destructive testing (NDT), and numerical simulation technologies, dynamic risk prevention and control throughout the entire lifecycle can be achieved. This preventive maintenance strategy extends equipment service life, reduces operational costs, and provides technical support for safe and sustainable development amid the global energy transition.

In recent years, research hotspots in the field of steel pipeline integrity assessment have focused on intelligentization, multi-scale collaboration, and adaptability to extreme environments. Key research directions include the following:

  • Digitalization and AI-driven technologies: Advanced applications of machine learning and IoT for real-time structural health monitoring and predictive maintenance.
  • Hydrogen–environment material compatibility: Investigating hydrogen embrittlement mechanisms and developing hydrogen-resistant alloys for steel pipelines and tanks.
  • Reliability enhancement in deep-sea and subsurface systems: Optimizing structural designs for pipelines under high-pressure, low-temperature, and corrosive deep-sea conditions.

Fracture control in supercritical CO2 pipe steels: Addressing phase transition-induced crack propagation and microbial corrosion prevention strategies.

This Special Issue aims to compile the latest global research advancements in the integrity assessment of steel pipelines and storage tanks, focusing on the following themes: risk assessment technologies for pipelines and storage tanks;integrity evaluation methods for emerging energy pipelines (LNG, H2, natural gas, and CO2) and associated storage systems; and inspection and monitoring technologies for pipeline and tank integrity.

Specific research topics include, but are not limited to, the following: defect assessment techniques for pipe steels; integrity evaluation methodologies for girth welds; fracture assessment approaches in pipeline engineering; statistical analysis and pattern recognition of failure incidents; novel technologies for detecting steel pipeline defects and stress monitoring; and data-driven innovative pathways for integrity management.

We look forward to your submissions.

Dr. Yi Shuai
Dr. Zhanfeng Chen
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • integrity evaluation
  • steel pipes
  • failure analysis
  • detection and monitoring
  • safety evaluation

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Published Papers (2 papers)

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Research

21 pages, 5434 KB  
Article
Statistical Evaluation of the Mechanical Properties of Welded and Unwelded ASTM A706 Reinforcing Steel Bars of Different Commercial Brands
by Lenin Abatta-Jacome, Daniel Rosero-Pazmiño, Jeison Rosero-Vivas, Bryan Fernando Chávez-Guerrero and Germán Omar Barrionuevo
Metals 2025, 15(12), 1307; https://doi.org/10.3390/met15121307 - 27 Nov 2025
Viewed by 444
Abstract
The future of reinforcing steel bars (rebar) is being shaped by technological advancements, sustainability initiatives, and evolving construction practices. Welding of rebar has a significant and evolving influence on construction practices, particularly with trends emphasizing speed, precision, and prefabrication. On the other hand, [...] Read more.
The future of reinforcing steel bars (rebar) is being shaped by technological advancements, sustainability initiatives, and evolving construction practices. Welding of rebar has a significant and evolving influence on construction practices, particularly with trends emphasizing speed, precision, and prefabrication. On the other hand, the variability in mechanical response depends not only on the chemical composition but also on the manufacturing and welding process. This study analyzed five commercial brands of ASTM A706 reinforcing steel rods available in the Ecuadorian market with different diameters (12, 14, 16, and 18 mm) subjected to tensile and bending tests. A total of 228 specimens were analyzed, and 114 samples were welded by shielded metal arc welding process using an E8018-C3 electrode, preparing the joint with a simple V-bevel at 45°. The tensile tests results allow for a comparison between the welded and unwelded steel bars, where it is identified that the welding process generates a slight decrease in the mechanical properties and increases the variability in the results, although it is emphasized that these variations do not affect compliance with the standards, since all the samples meet the mechanical strength requirements by being within the limits established by the ASTM A706/A706M standard. Full article
(This article belongs to the Special Issue Failure Analysis and Evaluation of Metallic Materials)
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27 pages, 3885 KB  
Article
Experimental and Machine Learning-Based Assessment of Fatigue Crack Growth in API X60 Steel Under Hydrogen–Natural Gas Blending Conditions
by Nayem Ahmed, Ramadan Ahmed, Samin Rhythm, Andres Felipe Baena Velasquez and Catalin Teodoriu
Metals 2025, 15(10), 1125; https://doi.org/10.3390/met15101125 - 10 Oct 2025
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Abstract
Hydrogen-assisted fatigue cracking presents a critical challenge to the structural integrity of legacy carbon steel natural gas pipelines being repurposed for hydrogen transport, posing a major barrier to the deployment of hydrogen infrastructure. This study systematically evaluates the fatigue crack growth (FCG) behavior [...] Read more.
Hydrogen-assisted fatigue cracking presents a critical challenge to the structural integrity of legacy carbon steel natural gas pipelines being repurposed for hydrogen transport, posing a major barrier to the deployment of hydrogen infrastructure. This study systematically evaluates the fatigue crack growth (FCG) behavior of API 5L X60 pipeline steel under varying hydrogen–natural gas (H2–NG) blending conditions to assess its suitability for long-term hydrogen service. Experiments are conducted using a custom-designed autoclave to replicate field-relevant environmental conditions. Gas mixtures range from 0% to 100% hydrogen by volume, with tests performed at a constant pressure of 6.9 MPa and a temperature of 25 °C. A fixed loading frequency of 8.8 Hz and load ratio (R) of 0.60 ± 0.1 are applied to simulate operational fatigue loading. The test matrix is designed to capture FCG behavior across a broad range of stress intensity factor values (ΔK), spanning from near-threshold to moderate levels consistent with real-world pipeline pressure fluctuations. The results demonstrate a clear correlation between increasing hydrogen concentration and elevated FCG rates. Notably, at 100% hydrogen, API X60 specimens exhibit crack propagation rates up to two orders of magnitude higher than those in 0% hydrogen (natural gas) conditions, particularly within the Paris regime. In the lower threshold region (ΔK ≈ 10 MPa·√m), the FCG rate (da/dN) increased nonlinearly with hydrogen concentration, indicating early crack activation and reduced crack initiation resistance. In the upper Paris regime (ΔK ≈ 20 MPa·√m), da/dNs remained significantly elevated but exhibited signs of saturation, suggesting a potential limiting effect of hydrogen concentration on crack propagation kinetics. Fatigue life declined substantially with hydrogen addition, decreasing by ~33% at 50% H2 and more than 55% in pure hydrogen. To complement the experimental investigation and enable predictive capability, a modular machine learning (ML) framework was developed and validated. The framework integrates sequential models for predicting hydrogen-induced reduction of area (RA), fracture toughness (FT), and FCG rate (da/dN), using CatBoost regression algorithms. This approach allows upstream degradation effects to be propagated through nested model layers, enhancing predictive accuracy. The ML models accurately captured nonlinear trends in fatigue behavior across varying hydrogen concentrations and environmental conditions, offering a transferable tool for integrity assessment of hydrogen-compatible pipeline steels. These findings confirm that even low-to-moderate hydrogen blends significantly reduce fatigue resistance, underscoring the importance of data-driven approaches in guiding material selection and infrastructure retrofitting for future hydrogen energy systems. Full article
(This article belongs to the Special Issue Failure Analysis and Evaluation of Metallic Materials)
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