Fatigue assessment of pre-corroded AlSi9Cu3 specimens incorporating
short crack propagation
Abstract
This study investigates the fatigue behavior of AlSi9Cu3 aluminum
die-cast alloy after pre-exposure to accelerated environmental
conditions (pre-corrosion). The research highlights the significant
impact of corrosion, particularly localized corrosion within the
microstructure, on the fatigue strength of this alloy. It introduces a
numerically efficient fatigue assessment method for pre-corroded
specimens, employing fracture mechanics principles. The investigations
reveal the significance of considering short crack propagation in
fatigue assessment especially for small corrosive defects. Polished
specimens were exposed to an acidic aqueous salt solution to simulate
accelerated real-world corrosive conditions. Experimental fatigue tests
revealed a 34 % reduction in long-life fatigue strength for
pre-corroded surface condition compared to polished condition. Numerical
simulations, which treated corrosion as a crack-like surface
imperfection, were used to estimate fatigue life and fatigue limit.
These simulations provide conservative estimates for the examined
initial flaws equal to the maximum corrosion depth. The variation in
long-life fatigue strength for all examined flaw geometries ranged from
13.7 % above to 22.2 % below the experimentally determined fatigue
strength of the pre-corroded surface. These findings highlight the
necessity of incorporating short crack propagation in fatigue
assessments, particularly for small corrosive defects, to ensure the
reliability and safety of components in corrosive environments.