Surface Characterization of 7075-T73 Aluminum Exposed to Anodizing Pretreatment Solutions

Localized corrosion damage in Type 7075-T73 aluminum alloy was investigated for various anodizing pretreatment solutions. The postexposure surface corrosion was characterized by use of scanning electron microscopy (SEM) examination. In addition, SEM and energy dispersive spectroscopy (EDS) were used for second-phase (constituent) particle identification for those found to induce pitting corrosion during solution exposure. The pitting mechanisms were identified as circumferential where the particles are noble with respect to the matrix phase and by selective dissolution where they are anodic. The designated category-1 degreasing and category-2 inhibited alkaline solutions did not initiate localized corrosion after 1200 s exposures. However, the category-3 high-pH NaOH and category-4 low-pH HNO₃ based solutions were found to initiate pitting attack, with the NaOH being significantly more aggressive. It was hypothesized that if the pits initiating during the pretreatment exposures were beyond a threshold size, on the order of 10-20 μm, a higher current density existed at these locations during subsequent electrochemical processes, thus resulting in larger and deeper pit structures. These surface defects are of primary concern with respect to accelerated fatigue crack nucleation. For smaller pits, on the order of 1-5 μm, the anodic process had a smoothing affect where the film growth tended to passivate the pits.     

Influence of surface treatments on fatigue life of Al 7010 alloy

The objective of the present work is to show the influence of machining and anodizing processes on fatigue life of alloy 7010-T7451. Two different cutting conditions were employed to obtain two different initial surface roughnesses. Degreasing, pickling and anodizing were then carried out. In the as machined condition, surface roughness is clearly effective in reducing fatigue life in this material. As the surface roughness increases fatigue life decreases and this effect is found to be more pronounced in high cycle fatigue where major portion of fatigue life is consumed in nucleating the cracks. Effects of pre-treatments, like degreasing and pickling employed prior to anodizing, on fatigue life of the given alloy were also studied. Fatigue curves showed that pickling had negative impact on fatigue life of specimens while degreasing showed no change in fatigue life. The small decrease in fatigue life of anodized specimens as compare to pickled specimens is attributed to brittle nature and micro-cracking of the coating. Scanning electron microscopic (SEM) examination revealed multi-site crack initiation for the pickled and anodized specimens. SEM examination also showed that pickling process attacked the grain boundaries and the inclusions present on the surface resulting in pits formation. These pits are of primary concern with respect to accelerated fatigue crack nucleation and subsequent anodized coating formation.     

环境对双相钢疲劳性能的影响

本文研究了自来水和3.5％NaCl水溶液分别在全浸和干湿交替状态下对热轧双相钢疲劳性能的影响.结果表明:与空气中的疲劳寿命相比,腐蚀环境有不同程度的降低作用,并以喷雾盐水影响最大.在相同腐蚀条件下,环境的影响随应力幅的降低而增强.马氏体抗疲劳断裂的能力高于铁素体.试样表面和断口的观察结果发现,腐蚀疲劳裂纹萌生与腐蚀坑密切相关,蚀坑以阳极溶解方式形成.     

S135钻杆钢预腐蚀后的弯曲疲劳性能

目的：考察有机盐钻井液对S135钻杆材料腐蚀及疲劳性能的影响。方法首先利用高温高压釜模拟有机盐钻井液井筒的工况环境,对疲劳试样进行预腐蚀,通过点蚀仪测定试样表面的腐蚀状况;然后利用旋转弯曲疲劳试验机在不同弯曲应力条件下对预腐蚀试样和未腐蚀试样的疲劳性能进行测试,算得不同存活率下的疲劳强度,并绘制不同存活率下的S-N曲线。用体视显微镜和扫描电镜观察预腐蚀试样和未腐蚀试样的疲劳断口形貌,进而得出S135钻杆材料表面腐蚀对其疲劳寿命的影响程度和影响机制。结果经过腐蚀的试样表面有较多腐蚀坑,腐蚀坑深度在0.4~0.7 mm之间。未腐蚀试样的疲劳强度为553 MPa,其疲劳断口只观察到单个疲劳裂纹源;腐蚀试样的疲劳强度为409 MPa,其疲劳断口观察到多个疲劳裂纹源。 S135钻杆材料腐蚀疲劳开裂敏感性指数为26%。结论经过高温高压有机盐钻井液环境腐蚀后,试样表面点蚀严重,腐蚀坑底部存在应力集中并导致裂纹源的形成,多个裂纹源的同时生长加快了裂纹的扩展,最终降低S135钻杆钢的疲劳强度。     

车轮铸钢铁基合金涂层改善热疲劳损伤的强化机制

用扫描电镜分析研究了铁基合金涂层对车轮铸钢材料抗热疲劳损伤机制的影响.结果表明,铁基涂层试样表面出现一些腐蚀坑和微裂纹,但并未出现剥落现象,涂层有效地阻碍了微裂纹向基体的传播,较好地避免了基体材料的热疲劳损伤.而在同等条件下未涂层试样不论是表面还是断口处都已遭受了较为严重的破坏.     

Corrosion fatigue behavior of a steel with sprayed coatings

This paper describes the corrosion fatigue behavior and fracture mechanisms of a steel with different sprayed coatings. Rotating bending fatigue tests were conducted in 3% NaCl solution using specimens of a medium carbon steel with sprayed coatings of a ceramic (Cr₂O₃), a cermet (WC-12%Co) and two metals (Ni-11 % P and Al-2% Zn). The corrosion fatigue process was basically the same for ceramic, cermet, and Ni-11 % P sprayed specimens. That is, the corrosive media could be supplied from the specimen surface to the substrate through cracks initiated during fatigue cycling and/or pores in the coatings, and thus corrosion pits were generated followed by subsequent crack initiation and growth in the substrate. The corrosion fatigue strength of ceramic sprayed specimens was slightly improved compared to that of the substrate steel because the under-coating (Ni-5%A1) could impede the penetration of the corrosive media although the ceramic coating had a poor resistance to cracking under cyclic loading. Cermet sprayed specimens also exhibited improved corrosion fatigue strength because of the high resistance to cracking and the low volume fraction of pores of the coating. In Ni-11 % Psprayed specimens, cracks were initiated in the coating even at low stress levels; thus the corrosion fatigue strength was the same as that of the substrate. Anodic dissolution took place in Al-2 % Zn coating because the coating was electrochemically poor, and thus the substrate was cathodically protected. Therefore, the corrosion fatigue strength of Al-2 % Zn sprayed specimens was enhanced to as high as the fatigue strength of the substrate in room air. Based on the experimental results, a dual-layer coating consisting of WC-12%Co and Al-2%Zn was fatigue tested. The coating was effective at low stress levels and exhibited long life under conditions where corrosion fatigue strength was critical.     

Analysis of pits induced stresses due to metal corrosion

The corrosion damage due to pitting is commonly observed in a wide range of aluminum alloys and structural steels that are being used for aerospace and naval structural applications. In order to predict the nucleation of cracks resulting from nucleation and growth of pits, there is a need to obtain the stress environment around pits. The objective of this study is to investigate the pits induced stresses responsible for possible crack nucleation using the photomicrographs of corroded aluminum 5059 alloy samples using stress analysis. An analysis procedure is developed using CAD and finite element analysis to predict stresses due to single and/or multiple corroded pits. The analysis was performed to investigate stress distributions on the corrosion surface as a function of sensitization time. The results obtained indicate that as the duration of the specimen sensitization increased from 50 days to 74 days, the highest stress levels have increased by about 56%. However, further increase in the sensitization time from 74 to 100 days has very little effect on the stress level. The observed severe exfoliation or the tearing of the sample surface layers in and around the pits is due to the nucleation and coalescence of fine cracks. The cracks are nucleated because of the production and the buildup of differential stresses along the sample thickness.     

Effect of corrosive environment on the fatigue crack initiation and propagation behavior of Al 5454-H32

Fatigue behavior of aluminum alloy 5454- H32 was studied under laboratory air and 3 % NaCl solution environment using smooth cylindrical and notched plate specimens. Presence of 3 % NaCl environment during fatigue loading drastically reduced alloy fatigue life. The deleterious effect was pronounced in both types of specimens in the long- life regions, where the fatigue lives were lowered by as much as a factor of 10. However, the sharply notched specimens showed only a modest reduction in fatigue life in corrosive environment. The severe influence of the corrosive environment in the long- life (low- stress) regime cannot be explained merely by the early initiation of the fatigue crack from surface pits; the environmental contribution in the early crack growth regime must also be considered an important factor. Fracture surface studies revealed extensive pitting and some secondary cracking in the crack initiation region. It was shown that lowered fatigue life in Al 5454- H32 occurs by early initiation of fatigue cracks from surface pits. In addition, a corrosion pitting and secondary cracking process may be operative in the small crack growth region. This could have enhanced the early crack growth rate and thus contributed to the lower fatigue life in the long- cycle region.     

CORROSION FATIGUE BEHAVIOR OF STAINLESS STEEL 3RE60 IN 3.5% SODIUM CHLORIDE SOLUTION

The corrosion fatigue behavior of stainless steel 3RE60 in 3.5%NaCl solution was studied at different cyclic stress levels. The results showed that both intergranular corrosion cracking and transgranular corrosion cracking initiated at the bottom of pits. The corrosion fatigue behavior of 3RE60 may be related to complex electrochemical and mechanical coupling effects between the three phases (austenite, ferrite and martensite), where martensite and ferrite were anodic in the corrosion cell and could be prone to crack under certain conditions.     

AM50镁合金孔挤压强化对其疲劳性能的影响

目的研究孔挤压处理对AM50镁合金疲劳性能的影响。方法对AM50镁合金进行孔挤压强化处理,使试样表面产生有益的残余压应力分布,并对残余应力的分布进行测定。对未处理镁合金及孔挤压镁合金进行疲劳性能测试,对比疲劳寿命及疲劳裂纹扩展速率,对疲劳断口进行扫描,分析孔挤压对AM50镁合金疲劳性能的影响。结果孔挤压处理后,孔周围残余压应力深度达到5.5 mm,且最大压应力值达-563 MPa,试样的疲劳寿命较未处理时增加了9倍,疲劳裂纹扩展速率大大降低,疲劳裂纹源由未处理时的孔表面转移到了挤压强化层内部。结论孔挤压可以明显抑制疲劳裂纹的萌生,延长疲劳寿命。     

电连接器4J29合金接触体断裂分析

采用体视显微镜、扫描电子显微镜、能谱分析仪、光学显微镜,对断裂的电连接器接触体进行表面和断口的宏微观形貌观察,断口表面化学成分及显微组织分析。结果表明:电连接器接触体在含Cl~-介质中发生应力腐蚀开裂,最终在工作振动应力作用下发生疲劳断裂;裂纹萌生阶段主要特征为腐蚀坑和沿晶,扩展阶段的主要特征为裂纹穿晶、分叉和疲劳条带。酸洗后腐蚀性Cl~-的残留与接触体表面镀层开裂导致接触体断裂。     

X80管线钢在近中性pH溶液中腐蚀行为研究

目的研究X80管线钢在近中性p H溶液中的腐蚀与应力腐蚀裂纹萌生行为。方法采用电化学实验和浸泡实验研究X80管线钢在近中性p H溶液中的腐蚀行为,采用慢应变速率拉伸实验研究X80管线钢在近中性p H溶液中,在自腐蚀电位和外加电位下的应力腐蚀裂纹萌生行为。结果 X80管线钢在近中性p H溶液中的极化曲线只有活化区,没有钝化区,其自腐蚀电位约为-750 m V,浸泡195天后,试样表面没有氧化膜出现,但是观察到点蚀坑。在自腐蚀电位下,X80管线钢试验表面有大量的应力腐蚀裂纹;在-500 m V阳极外加电位下,X80管线钢试验表面几乎没有观察到应力腐蚀裂纹;在-850 m V阴极外加电位下,X80管线钢试验表面的应力腐蚀裂纹很少,但是随着外加阴极电位负移到-1300 m V时,X80管线钢试验表面的应力腐蚀裂纹增多。结论 X80管线钢在近中性p H溶液中发生均匀腐蚀,但是夹杂物剥落能在X80管线钢表面形成点蚀坑。在近中性p H溶液中,在自腐蚀电位下,X80管线钢应力腐蚀裂纹萌生敏感性最强;外加阴极电位抑制应力腐蚀裂纹萌生,但是随着外加阴极电位的负移,应力腐蚀裂纹萌生敏感性增强;外加阳极电位下,由于均匀腐蚀的作用,应力腐蚀裂纹萌生敏感性较弱。     

环氧涂层处理的Mg-3Al-1Zn镁合金在齿轮油中的腐蚀疲劳性能(英文)

研究环氧涂层处理后的Mg-3Al-1Zn合金在齿轮油环境下的腐蚀疲劳行为。采用扫描电子显微镜(SEM)观察疲劳试验后试样的腐蚀形貌及疲劳断口特征,并通过能谱仪(EDS)分析试样在齿轮油中的腐蚀产物成分。分析环氧涂层处理前、后2种试样的腐蚀疲劳性能和疲劳裂纹萌生机制。结果表明:经环氧涂层处理后,试样在齿轮油中的腐蚀疲劳极限高于未处理试样的。这是由于环氧涂层可以将镁合金与周围腐蚀环境良好地隔离。环氧涂层的力学性能比镁合金的差,这是疲劳裂纹优先从环氧涂层萌生的重要原因。另外,齿轮油的润滑作用可以使环氧涂层产生剥落现象。     

Evaluation of an Ultrasound-Aided Deep Rolling Process for Anti-Fatigue Applications

An ultrasound-aided deep rolling process (UADR) for anti-fatigue applications was developed and used for surface enhancement of titanium alloy specimens. The rotating bending fatigue test was performed for the UADR-treated and untreated fatigue specimens. Fractography of the fatigue-fractured specimens was investigated via scanning electronic microscopy (SEM). Surface and subsurface residual stress distributions after UADR treatment were measured by X-ray diffraction method. Surface morphology and roughness were observed and measured via SEM micrograph and a Talysurf roughness tester, respectively. The results showed that a deep layer of residual compressive stress developed and surface roughness was reduced after UADR treatment. Fatigue strength of the titanium alloy specimens was substantially improved. The fractographic examination of the fatigue-fractured specimens showed that the UADR-treated specimens developed finer fatigue striations than the untreated specimen.     

植入铸造不锈钢髋关节断裂失效事例分析

利用ＳＥＭ对实际使用时断裂的髋关节的断口和表面进行了分析，认为此关节的断裂为以弯曲应力为主的腐蚀疲劳断裂。疲劳裂纹首先在表面的腐蚀点孕育产生，应力和腐蚀的共同作用使得裂纹得以扩展断裂。     

Coating residual stress effects on fatigue performance of 7050-T7451 aluminum alloy

The tendency of the aircraft industry is to enhance customer value by improving performance and reducing environmental impact. In view of availability, aluminum alloys have a historically tendency to faster insertion due to their lower manufacturing and operated production infrastructure. In landing gear components, wear and corrosion control of many components is accomplished by surface treatments of chrome electroplating on steel or anodizing of aluminum. One of the most interesting environmentally safer and cleaner alternatives for the replacement of hard chrome plating or anodizing is tungsten carbide thermal spray coating, applied by the high velocity oxy fuel (HVOF) process. However, it was observed that residual stresses originating from these coatings reduce the fatigue strength of a component.An effective process as shot peening treatment, considered to improve the fatigue strength, pushes the crack sources beneath the surface in most of medium and high cycle cases, due to the compressive residual stress field induced. The objective of this research is to evaluate a tungsten carbide cobalt (WC-Co) coating applied by the high velocity oxy fuel (HVOF) process, used to replace anodizing. Anodic films were grown on 7050-T7451 aluminum alloy by sulfuric acid anodizing, chromic acid anodizing and hard anodizing. The influence on axial fatigue strength of anodic films grown on the aluminum alloy surface is to degrade the stress-life performance of the base material. Three groups of specimens were prepared and tested in axial fatigue to obtain S-N curves: base material, base material coated by HVOF and base material shot peened and coated.Experimental results revealed increase in the fatigue strength of Al 7050-T7451 alloy associated with the WC 17% Co coating. On the other hand, a reduction in fatigue life occurred in the shot peened and coated condition. Scanning electron microscopy technique and optical microscopy were used to observe crack origin sites, thickness and coating/substrate adhesion.     

高速列车车轴用EA4T钢腐蚀疲劳性能研究

目的 研究腐蚀环境中EA4T车轴钢疲劳性能,为车轴的腐蚀检测和使用寿命评估提供依据.方法 采用旋转弯曲疲劳试验机,在人造雨水模拟的腐蚀环境和空气环境中,对EA4T车轴钢试样进行疲劳试验,以获得不同环境下试样的疲劳S-N曲线、表面损伤以及裂纹扩展规律.然后对扩展裂纹进行概率统计,通过扫描电镜对疲劳失效的断口进行观察,并分析对比不同环境中裂纹扩展门槛值的变化.结果 空气环境中,试样的疲劳极限为355 MPa,而在腐蚀环境中,试样不存在疲劳极限,107循环周次对应的疲劳强度降低到245 MPa,相比空气环境中降低了31％.Gumbel分布统计与Weibull双参数分布统计相比,更适合描述EA4T车轴钢试样表面腐蚀裂纹长度随加载次数的变化.腐蚀环境中,疲劳裂纹萌生于表面腐蚀坑,并存在多个裂纹源.腐蚀环境显著降低了试样裂纹扩展门槛值,空气环境下,该值为6.29 MPa·m1/2,腐蚀环境下降低到4.1 MPa·m1/2.结论 腐蚀环境降低EA4T钢疲劳寿命的主要原因是,腐蚀环境降低了裂纹扩展门槛值,加快了裂纹萌生以及短裂纹扩展.而当裂纹达到一定长度时,腐蚀环境对裂纹扩展几乎没有影响.     

Electrochemistry of deformed smooth surfaces and short corrosion fatigue crack growth behaviour

Abstract

The polarisation characteristics for a deformed smooth surface of a 0·2% carbon steel in an artificial sea water have been determined under static and cyclic loading conditions. The influence of strain level and loading frequency on anodic and cathodic Tafel constants, corrosion current density, and corrosion potential is described. Based on these data, the conditions for corrosion fatigue testing which corresponded to a maximum synergism between surface deformation and anodic dissolution were determined. Corrosion fatigue tests, which were conducted under both constant potential and constant current density conditions have shown that a process of metal dissolution plays a determining role in the short corrosion fatigue crack growth behaviour. An experimentally based criterion is proposed involving the development of a short corrosion fatigue crack, of characteristic size, which is associated with the spacing between the major microstructural barriers. This criterion is a function of both shear stress and the parameters controlling the anodic dissolution process on a cyclically deformed smooth suiface. An expression predicting the formation of short corrosion fatigue cracks is presented which takes into account the synergistic action of shear stress and the corrosion process.     

火焰喷焊对碳钢疲劳寿命的影响

对三种不同基材状态的45~3钢经表面火焰喷焊Ni60后的疲劳性能及腐蚀疲劳性能变化的研究,表明强度高的调质态基材喷焊后的疲劳极限下降7%,而正火态和轧态基材喷焊后疲劳极限提高14%。当有3.5%NaCl腐蚀介质存在时,不管基材强度高或低,表面喷焊都使材料的腐蚀疲劳强度(10~7寿命)提高30%以上。文中通过断口金相分析阐明喷焊后基材表面组织结构变化及其对疲劳裂纹形成及扩展的影响,讨论了Ni60喷焊层在腐蚀疲劳过程的行为,为喷焊工艺在工业中的应用提供了依据。     

Effect of pitting corrosion on fatigue performance of shot-peened aluminium alloy 7075-T651

Pitting corrosion has a major influence on aging of structural elements made of high-strength aluminium alloys as corrosion pits lead to earlier fatigue crack initiation under tensile dynamic loading. A cause of fatigue crack initiation in a corrosive medium is a stress concentration at a corroded area. In order to improve material resistance to corrosion fatigue it is necessary to reduce pit-tip stresses. To eliminate or reduce pit stresses, cold surface hardening by shot peening was proposed. The objective of the present study was to investigate the effect of surface hardening by shot peening on electrochemical stability and corrosion fatigue properties of high-strength aluminium alloy 7075-T651 in the corrosive environment of a chloride solution. The results obtained show a favourable influence of shot-peening treatment on corrosion fatigue properties. Induced compressive residual stresses in the surface layer retard the initiation of fatigue cracks, and so the fatigue life improvement of structural elements made of high-strength aluminium alloys was observed.