PREPARED BY
NAME: PATEL MITESH P.
[Link]: 916
SUBJECT: ELECTOMETALLURGY & CORROSION
In materials science, fatigue is the progressive and localized structural damage that occurs when a material is subjected to cyclic loading.
The nominal maximum stress values are less than the ultimate tensile stress limit, and may be below the yield stress limit of the material.
The premature failure of a material from the exposure to the combined action of corrosive environment and cyclic ( or Alternating) stress is called Corrosion Fatigue. The number of cycles for failure decreases as the stress is increased. Below a certain stress the metal will last indefinitely. This level is termed as 'Endurance Limitof the material.
FATIGUE FAILURE:
THEY SHOW LARGER SMOOTH AREA AND SMALLER AREA WHICH HAS ROUGHENED AND SOMEWHAT CRYSTALLINE APPEARANCE
CORROSION FATIGUE: THEY SHOW LARGER AREA COVERED WITH CORROSION PRODUCTS AND SMALLER AREA RESULTING FROM FINAL BRITTLE FRACTURE.
Ships Offshore platforms Drilling rigs Navigation tuners Aircrafts Submarine pipelines Communication equipments Heat exchanger tubes Pump shafts Alternate dry and wet zones Pump shafts Rotors Steam turbine blades Boiler and steel equipment. Nuclear parts
ASTM defines fatigue life, Nf , as the number of stress cycles of a specified character that a specimen sustains before failure of a specified nature occurs.
One method to predict fatigue life of materials is the Uniform Material Law (UML).
UML was developed for fatigue life prediction of aluminum and titanium alloys by the end of 20th century and extended to high-strength steels.
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The fatigue life of steel and other ferrous materials usually becomes independent of stress at low stress levels. As shown in figure , this is called fatigue limit. Nonferrous metals such as aluminum and magnesium do not possess a fatigue limit.
Cyclic stress state Geometry Surface quality Material Type Residual stresses Size and distribution of internal defects Direction of loading Grain size Environment Temperature
Stress Ratio
The most commonly used stress ratio is R, the ratio of the minimum stress to the maximum stress R= ( S min. / S max. ).
If the stresses are fully reversed, then R = -1. If the stresses are partially reversed, R = a negative number less than 1.
If the stress is cycled between a maximum stress and no load, R = zero.
If the stress is cycled between two tensile stresses, R = a positive number less than 1.
Mechanical
Corosion fatigue
Environmental
Metallurgical
Evan has given electrochemical mechanism metal according to which failure takes place in two stages.
[Link] first stage the pits of various depth are formed on the surface of metal as a result of corrosion.
[Link] second stage there is appearance and development of cracks.
The main distinguishing feature of corrosion fatigue cracks is the presence of several cracks near the fracture. In a normal fatigue failure, usually one crack is present. The corrosion fatigue cracks run parallel to each other and are aligned perpendicular to the direction of principal stress. Corrosion fatigue cracks in carbon steels often propagate generally from the base of corrosion pits.
Generally, the fatigue corrosion cracks in certain steels are transgranular in nature .
The striations formed in corrosion fatigue failure are less pronounced than in normal fatigue failure, as shown by electron microscopy.
The cracks generally initiate at the surface where the stress is maximum. The fractured surface is dull in appearance and may contain corrosion products These cracks occur usually in groups. Corrosion fatigue cracks have blunt edges.
In this figure, curve A shows the fatigue behavior of a material tested in air. A fatigue threshold or limit is seen in A corresponding to the horizontal part of the curve. Curves B and C represent the fatigue behavior of the same material in two corrosive environments. In curve B, the fatigue failure at high stress levels is retarded and the fatigue limit is eliminated. In curve C, the whole curve is shifted to the left indicating a general lowering in the fatigue strength, accelerated initiation at higher stresses and elimination of a fatigue limit.
Effect of Corrosion on S-N Diagram
Discontinuities in metal, such as near the surface.
Inclusions or second-phase particles. Scratches on a metal surface. Sites of pitting or intergranular corrosion. Twin boundaries.
Crack Propagation Studies in Corrosin Fatigue
In normal fatigue testing of smooth specimens, about 90% of the life is spent in crack nucleation and only the remaining 10 % in crack propagation. However , in corrosion fatigue , crack nucleation is facilitated by corrosion and typically about 10 % of life is sufficient for this stage. The rest, 90 % of life is spent in crack propagation. Fatigue crack grows in a stable fashion below the critical stress intensity factor for fracture (fracture toughness), the process is called sub-critical crack growth.
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In this log-log plot,the crack propagation velocity is plotted against the applied stress intensity range.
Three stages may be visualized in this plot. Near the threshold,crack propagation velocity increases considerably with increasing stress intensity range where the curve is nearly linear and follows the Paris' law where crack propagation velocity increases rapidly with stress intensity range leading to fracture at the fracture toughness value.
Corrosion fatigue can be reduced by increasing tensile strength by
alloy addition corrosion inhibitors cathodic protection
All of above reduce pitting. Also surface treatment like
plating cladding nitriding shot-peening
There is a great demand for high static strength materials and a desire for higher structural performance from these materials. an understanding of corrosion fatigue and of fatigue-environment interaction is extremely important for selection of materials resistant to corrosion fatigue.
This phenomenon limits the use, particularly of steels, in marine environment, chemical and petrochemical industries.
Corrosion Engineering By Mars G. Fontana. Principle of Corrosion Engineering and corrosion control By Zaki Ahmad. Google search
