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Abstract Hydrogen embrittlement (HE) is a major issue for the mechanical integrity of high-strength alloys exposed to hydrogen-rich environments, with diffusion and trapping of hydrogen being critical phenomena. Here, the role of microstructure on hydrogen diffusion, trapping and embrittlement in additively manufactured (AM) and wrought Inconel 718 is compared, revealing the key role played by dislocation cells. Trapping behaviour in hydrogen-saturated alloys is analysed by thermal desorption spectroscopy and numerical simulations. A high density of hydrogen traps in cell walls, attributed to dense dislocations and Laves phases, are responsible for the local accumulation of hydrogen, causing significant loss in strength, and triggering cracking along dislocation cell walls. The influential role of dislocation cells alters fracture behaviour from intergranular in the wrought alloy to intragranular for the AM alloy, due to the large proportion of dislocation cells in AM alloys. In addition, the cellular network of dislocations accelerates hydrogen diffusion, enabling faster and deeper penetration of hydrogen in the AM alloy. These results indicate that the higher HE susceptibility of nickel superalloys is intrinsically associated with the interaction of hydrogen with dislocation walls.

Environmentally assisted cracking phenomena are widespread across the transport, defence, energy and construction sectors. However, predicting environmentally assisted fractures is a highly cross-disciplinary endeavour that requires resolving the multiple material-environment interactions taking place. In this manuscript, an overview is given of recent breakthroughs in the modelling of environmentally assisted cracking. The focus is on the opportunities created by two recent developments: phase field and multi-physics modelling. The possibilities enabled by the confluence of phase field methods and electro-chemo-mechanics modelling are discussed in the context of three environmental assisted cracking phenomena of particular engineering interest: hydrogen embrittlement, localised corrosion and corrosion fatigue. Mechanical processes such as deformation and fracture can be coupled with chemical phenomena like local reactions, ionic transport and hydrogen uptake and diffusion. Moreover, these can be combined with the prediction of an evolving interface, such as a growing pit or a crack, as dictated by a phase field variable that evolves based on thermodynamics and local kinetics. Suitable for both microstructural and continuum length scales, this new generation of simulation-based, multi-physics phase field models can open new modelling horizons and enable Virtual Testing in harmful environments.

The phase field fracture method is attracting significant interest. Phase field approaches have enabled predicting - on arbitrary geometries and dimensions - complex fracture phenomena such as crack branching, coalescence, deflection and nucleation. In this work, we present a simple and robust implementation of the phase field fracture method in the commercial finite element package Abaqus. The implementation exploits the analogy between the phase field evolution law and the heat transfer equation, enabling the use of Abaqus’ in-built features and circumventing the need for defining user elements. The framework is general, and is shown to accommodate different solution schemes (staggered and monolithic), as well as various constitutive choices for preventing damage under compression. The robustness and applicability of the numerical framework presented is demonstrated by addressing several 2D and 3D boundary value problems of particular interest. Focus is on the solution of paradigmatic case studies that are known to be particularly demanding from a convergence perspective. The results reveal that our phase field fracture implementation can be readily combined with other advanced computational features, such as contact, and deliver robust and precise solutions. The code developed can be downloaded from www.empaneda.com/codes.