Effects of Coatings on the High-Cycle Fatigue Life of Threaded Steel Samples

Martin Alexander Eder*, Philipp Ulrich Haselbach, O. V. Mishin

*Corresponding author for this work

Research output: Contribution to journalJournal articleResearchpeer-review

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Abstract

In this work, high-cycle fatigue is studied for threaded cylindrical high-strength steel samples coated using three different industrial processes: black oxidation, normal-temperature galvanization and high-temperature galvanization. The fatigue performance in air is compared with that of uncoated samples. Microstructural characterization revealed the abundant presence of small cracks in the zinc coating partially penetrating into the steel. This is consistent with the observation of multiple crack initiation sites along the thread in the galvanized samples, which led to crescent type fracture surfaces governed by circumferential growth. In contrast, the black oxidized and uncoated samples exhibited a semicircular segment type fracture surface governed by single-sided growth with a significantly longer fatigue life. Numerical fatigue life prediction based on an extended Paris-law formulation has been conducted on two different fracture cases: 2D axisymmetric multisided crack growth and 3D single-sided crack growth. The results of this upper-bound and lower-bound approach are in good agreement with experimental data and can potentially be used to predict the lifetime of bolted components.
Original languageEnglish
JournalJournal of Materials Engineering and Performance
Volume27
Issue number6
Pages (from-to)3184-3198
Number of pages15
ISSN1059-9495
DOIs
Publication statusPublished - 2018

Keywords

  • Coating
  • Cracks
  • High-cycle fatigue failure analysis
  • High-strength steel bolts
  • Life prediction
  • Microscopy
  • Modeling and simulation

Cite this

@article{be41240b76784e45ab5a7620cfdc50c4,
title = "Effects of Coatings on the High-Cycle Fatigue Life of Threaded Steel Samples",
abstract = "In this work, high-cycle fatigue is studied for threaded cylindrical high-strength steel samples coated using three different industrial processes: black oxidation, normal-temperature galvanization and high-temperature galvanization. The fatigue performance in air is compared with that of uncoated samples. Microstructural characterization revealed the abundant presence of small cracks in the zinc coating partially penetrating into the steel. This is consistent with the observation of multiple crack initiation sites along the thread in the galvanized samples, which led to crescent type fracture surfaces governed by circumferential growth. In contrast, the black oxidized and uncoated samples exhibited a semicircular segment type fracture surface governed by single-sided growth with a significantly longer fatigue life. Numerical fatigue life prediction based on an extended Paris-law formulation has been conducted on two different fracture cases: 2D axisymmetric multisided crack growth and 3D single-sided crack growth. The results of this upper-bound and lower-bound approach are in good agreement with experimental data and can potentially be used to predict the lifetime of bolted components.",
keywords = "Coating, Cracks, High-cycle fatigue failure analysis, High-strength steel bolts, Life prediction, Microscopy, Modeling and simulation",
author = "Eder, {Martin Alexander} and Haselbach, {Philipp Ulrich} and Mishin, {O. V.}",
year = "2018",
doi = "10.1007/s11665-018-3399-2",
language = "English",
volume = "27",
pages = "3184--3198",
journal = "Journal of Materials Engineering and Performance",
issn = "1059-9495",
publisher = "Springer New York",
number = "6",

}

Effects of Coatings on the High-Cycle Fatigue Life of Threaded Steel Samples. / Eder, Martin Alexander; Haselbach, Philipp Ulrich; Mishin, O. V.

In: Journal of Materials Engineering and Performance, Vol. 27, No. 6, 2018, p. 3184-3198.

Research output: Contribution to journalJournal articleResearchpeer-review

TY - JOUR

T1 - Effects of Coatings on the High-Cycle Fatigue Life of Threaded Steel Samples

AU - Eder, Martin Alexander

AU - Haselbach, Philipp Ulrich

AU - Mishin, O. V.

PY - 2018

Y1 - 2018

N2 - In this work, high-cycle fatigue is studied for threaded cylindrical high-strength steel samples coated using three different industrial processes: black oxidation, normal-temperature galvanization and high-temperature galvanization. The fatigue performance in air is compared with that of uncoated samples. Microstructural characterization revealed the abundant presence of small cracks in the zinc coating partially penetrating into the steel. This is consistent with the observation of multiple crack initiation sites along the thread in the galvanized samples, which led to crescent type fracture surfaces governed by circumferential growth. In contrast, the black oxidized and uncoated samples exhibited a semicircular segment type fracture surface governed by single-sided growth with a significantly longer fatigue life. Numerical fatigue life prediction based on an extended Paris-law formulation has been conducted on two different fracture cases: 2D axisymmetric multisided crack growth and 3D single-sided crack growth. The results of this upper-bound and lower-bound approach are in good agreement with experimental data and can potentially be used to predict the lifetime of bolted components.

AB - In this work, high-cycle fatigue is studied for threaded cylindrical high-strength steel samples coated using three different industrial processes: black oxidation, normal-temperature galvanization and high-temperature galvanization. The fatigue performance in air is compared with that of uncoated samples. Microstructural characterization revealed the abundant presence of small cracks in the zinc coating partially penetrating into the steel. This is consistent with the observation of multiple crack initiation sites along the thread in the galvanized samples, which led to crescent type fracture surfaces governed by circumferential growth. In contrast, the black oxidized and uncoated samples exhibited a semicircular segment type fracture surface governed by single-sided growth with a significantly longer fatigue life. Numerical fatigue life prediction based on an extended Paris-law formulation has been conducted on two different fracture cases: 2D axisymmetric multisided crack growth and 3D single-sided crack growth. The results of this upper-bound and lower-bound approach are in good agreement with experimental data and can potentially be used to predict the lifetime of bolted components.

KW - Coating

KW - Cracks

KW - High-cycle fatigue failure analysis

KW - High-strength steel bolts

KW - Life prediction

KW - Microscopy

KW - Modeling and simulation

U2 - 10.1007/s11665-018-3399-2

DO - 10.1007/s11665-018-3399-2

M3 - Journal article

VL - 27

SP - 3184

EP - 3198

JO - Journal of Materials Engineering and Performance

JF - Journal of Materials Engineering and Performance

SN - 1059-9495

IS - 6

ER -