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

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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.

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Abbreviations

a :

Crack length (mm)

a 0 :

Intrinsic crack length (mm)

a c :

Critical crack length at fracture

a e :

Effective crack length (mm)

a i :

Crack length increment (mm)

a ini :

Initial crack length (mm)

b :

Basquin law exponent

c :

Notch depth (mm)

d :

Nominal diameter or diameter of steel core (mm)

d 2 :

Pitch diameter (mm)

r e :

Effective radius (mm)

k t :

Theoretical stress concentration factor

l c :

Distance between cracks in coating (mm)

n, p, q :

Stage-1, Stage-2 and Stage-3 growth exponents

n x , n y :

Number of divisions in x-direction and y-direction, respectively

r :

Notch root radius (mm)

t c :

Coating thickness (mm)

x, y :

Cartesian coordinates in the crack plane (mm)

A eff :

Effective cross-sectional area (mm2)

C th, C :

Stage-1 and Stage-2 growth parameter

\(\hat{C}\) :

Basquin law parameter

E c :

Elastic modulus of zinc coating (MPa)

E s :

Elastic modulus of steel (substrate) MPa

F a :

Load amplitude (kN)

F m :

Mean load (kN)

G max, G c :

Maximum Mode-1 SERR at peak load or critical SERR release rate (J/mm2)

K c :

Fracture toughness of steel material (MPa \(\sqrt {\text{mm}}\))

K max :

Maximum stress intensity factor at peak load (MPa \(\sqrt {\text{mm}}\))

K op :

Opening stress intensity factor (MPa \(\sqrt {\text{mm}}\))

L :

Length (mm)

N, N tot :

Number of cycles, number of cycles to failure

R :

Load ratio/R-ratio

T :

Ambient temperature (K)

T sol :

Solidification temperature of coating (K)

X, Y, Z :

Cartesian coordinates in the sample coordinate system (mm)

Α :

Constraint factor α = 1 for plane stress or crack closure parameter or tensile stress concentration pre-factor α = 2

α c :

Linear coefficient of thermal expansion of coating (K−1)

α s :

Linear coefficient of thermal expansion of substrate (K−1)

ε ij :

Green strain tensor

δ ij :

Kronecker delta

∆α :

Incremental crack spacing or fracture quantum (m)

∆σ :

Stress range (MPa)

∆σ e :

Endurance limit range (MPa)

∆K :

Stress intensity factor range (MPa \(\sqrt {\text{mm}}\))

∆K 1 :

Stress intensity factor threshold range for R = 1 (MPa \(\sqrt {\text{mm}}\))

∆K th :

Stress intensity factor threshold range for R ≥ 0 (MPa \(\sqrt {\text{mm}}\))

ν :

Poisson’s ratio

σ 0 :

Flow stress of parent material (MPa)

σ a :

Nominal stress amplitude (MPa)

σ e :

Endurance limit amplitude (MPa)

σ m :

Nominal mean stress (MPa)

σ max :

Maximum nominal stress level (MPa)

σ min :

Minimum nominal stress level (MPa)

σ u :

Nominal ultimate tensile strength (MPa)

σ y :

Nominal yield strength (MPa)

σ T :

Maximum thermal equi-biaxial stress in coating (MPa)

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Acknowledgments

This work was supported by the Department of Wind Energy within the cross-sectional activity program. The authors acknowledge H.L. Toftegaard, J. Sjølin and L. Lorentzen for their technical assistance.

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Authors and Affiliations

  1. Department of Wind Energy, Technical University of Denmark, 4000, Roskilde, Denmark

    M. A. Eder & P. U. Haselbach

  2. Department of Mechanical Engineering, Technical University of Denmark, 2800, Kgs. Lyngby, Denmark

    O. V. Mishin

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  1. M. A. Eder
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Correspondence to M. A. Eder.

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Eder, M.A., Haselbach, P.U. & Mishin, O.V. Effects of Coatings on the High-Cycle Fatigue Life of Threaded Steel Samples. J. of Materi Eng and Perform 27, 3184–3198 (2018). https://doi.org/10.1007/s11665-018-3399-2

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