Characterization of ASME SA 240 (UNS S 32100) Explosion Cladded to ASME SA 542 Type D Class A for Extreme Hydrogen Service: Final ASTM G146 Results and Comprehensive Analysis

Abstract Selecting appropriate materials for heavy-wall pressure vessels operating in high-pressure, high-temperature (HTHP) hydrogen environments is crucial due to the risks of embrittlement and disbonding at the cladding interface. Hydrotreatment or hydrocracking reactors, often lined with austenitic stainless steel, face significant challenges in preventing corrosion and maintaining integrity. This study characterizes the Explosion Welding (EXW) interface under these extreme conditions. More than 150 tests, including ASTM G146 disbonding and comprehensive macro/microstructural evaluations, were conducted to assess the material's performance. This paper complements previous work by concluding the study with final G146 test results and detailed macro/microstructural examinations, providing a thorough understanding of the interface's behavior in HTHP hydrogen service environments. These findings support the use of EXW as a reliable cladding technology for hydrogen service applications, ensuring the longevity and safety of pressure vessels in the oil and gas industry.