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Electrochemical Fatigue Crack Treatment Konstantin Dolgan Louisiana Tech University Louisiana Tech University Louisiana Tech Digital Commons Doctoral Dissertations Graduate School Spring 2015 Electrochemical fatigue crack treatment Konstantin Dolgan Louisiana Tech University Follow this and additional works at: https://digitalcommons.latech.edu/dissertations Part of the Mechanical Engineering Commons Recommended Citation Dolgan, Konstantin, "" (2015). Dissertation. 225. https://digitalcommons.latech.edu/dissertations/225 This Dissertation is brought to you for free and open access by the Graduate School at Louisiana Tech Digital Commons. It has been accepted for inclusion in Doctoral Dissertations by an authorized administrator of Louisiana Tech Digital Commons. For more information, please contact [email protected]. ELECTROCHEMICAL FATIGUE CRACK TREATMENT by Konstantin Dolgan, B.S., M.S. A Dissertation Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy COLLEGE OF ENGINEERING AND SCIENCE LOUISIANA TECH UNIVERSITY May 2015 ProQuest Number: 3664373 All rights reserved INFORMATION TO ALL USERS The quality of this reproduction is dependent upon the quality of the copy submitted. In the unlikely event that the author did not send a complete manuscript and there are missing pages, these will be noted. Also, if material had to be removed, a note will indicate the deletion. ProQuestQue ProQuest 3664373 Published by ProQuest LLC(2015). Copyright of the Dissertation is held by the Author. All rights reserved. This work is protected against unauthorized copying under Title 17, United States Code. Microform Edition © ProQuest LLC. ProQuest LLC 789 East Eisenhower Parkway P.O. Box 1346 Ann Arbor, Ml 48106-1346 LOUISIANA TECH UNIVERSITY THE GRADUATE SCHOOL 23 January 2015 Date We hereby recommend that the thesis prepared under our supervision by____________________________________ Konstantin Dolgan______________ entitled_______________________ Electrochemical Fatigue Crack Treatment be accepted in partial fulfillment of the requirements for the Degree of _________ Ph.D. Materials and Infrastructure Systems _____________ Supervisor o f Thesis Research Head o f Department Department datiotf concurred in Advisory Committee Approved: Approved: iraduate StudiesDirj Director o f the Graduate School lean o f the College GS Form 13 2/97 ABSTRACT Fatigue is responsible for at least 50% of all mechanical and 90% of all metallic failures. Fatigue cracks often start at stress concentrations, and without timely and appropriate remediation, tend to exhibit relatively fast propagation that leads to property damage and sometimes serious accidents. The objective of this research was to develop a new method of fatigue crack treatment in steel structures and estimate its efficiency and limitations. The method was based on placing fatigue cracks under compression by depositing nickel onto the surfaces of the cracks. The proposed method was applied to ASTM E399 compact-tension specimens machined from ASTM A36 steel. This study found that the method was able to arrest fatigue crack propagation. Fatigue crack arrest period varied from 2,000 to 30,000 cycles. The fatigue life of the specimens was extended for up to 55,000 cycles. In many cases the re-initiation life of fatigue cracks after treatment was similar to the crack initiation life obtained from the V-shaped starter notches. A power law relationship was developed that successfully correlates the fatigue crack arrest life and the stress intensity factor range applied for post-treatment load cycling. Fatigue crack packing with nickel resulted in significant reduction of stress concentration factors of the cracks. Spectroscopic analysis confirmed the presence of nickel in electrochemically treated fatigue cracks. The amount of nickel deposited was found to be non-uniform along the length of the cracks. This study found that an elastic finite element analysis (FEA) supported the notion of compressive stresses being developed at the crack tip and of a significant reduction in the stress concentration factor of the fatigue crack due to application of this treatment method. FEA has also supported the expectation that increasing the dosage of crack packing material would tend to result in a longer crack re­ initiation period. The proposed method of electrochemical fatigue crack treatment was found to be beneficial in terms of improved corrosion resistance of treated specimens as long as the treatment was uniform and continuous. The average general corrosion rate of nickel-plated ASTM A36 steel specimens that were uncracked was 80% lower than that of the non-plated cases. The discontinuous deposition observed within cracks was expected to promote localized corrosion of the A36 base metal. Future work will examine the use of deposition candidates with less of a tendency toward dissimilar metal corrosion. APPROVAL FOR SCHOLARLY DISSEMINATION The author grants to the Prescott Memorial Library o f Louisiana T ech University the right to reproduce, by appropriate methods, upon request, any or all portions o f this Thesis. It is understood that “proper request” consists o f the agreement, on the part o f the requesting party, that said reproduction is for his personal use and that subsequent reproduction will not occur without written approval o f the author o f this Thesis. Further, any portions o f the Thesis used in books, papers, and other works must be appropriately referenced to this Thesis. Finally, the author o f this Thesis reserves the right to publish freely, in the literature, at any time, any or all portions o f this Thesis. A u th o r Date /d - / i 6 " Z & /S GS Form 14 (5/03) DEDICATION I dedicate this dissertation to my parents and my lovely wife. This achievement wouldn’t be possible without their continuous support. v TABLE OF CONTENTS ABSTRACT.............................................................................................................................iii DEDICATION.......................................................................................................................... v LIST OF TABLES................................................................................................................ viii LIST OF FIGURES.................................................................................................................ix CHAPTER 1 INTRODUCTION............................................................................................. 1 CHAPTER 2 BACKGROUND...............................................................................................2 2.1 Metal Fatigue..................................................................................................................2 2.1.1 Motivation to Study Metal Fatigue ........................................................................2 2.1.2 Crack Initiation ....................................................................................................... 5 2.1.3 Linear Elastic Fracture Mechanics Concepts ........................................................ 8 2.1.4 Crack Tip Plasticity ............................................................................................... 17 2.1.5 Fracture Toughness ............................................................................................... 18 2.1.6 Fatigue Crack Growth ...........................................................................................20 2.1.7 Crack Growth Life Integration .............................................................................28 2.1.8 Mean Stress Effect ................................................................................................30 2.1.9 Cyclic Plastic Zone ...............................................................................................33 2.1.10 Crack Closure ...................................................................................................... 36 2.1.11 Corrosion Fatigue ................................................................................................41 2.1.12 Fatigue Crack Repair Techniques ......................................................................43 2.2 Electrochemistry .......................................................................................................... 46 2.2.1 Definition and Fundamentals of Electrochemistry ............................................. 46 2.2.2 Electrochemical Cells ...........................................................................................47 2.2.3 Electrodeposition of Metals, Electroplating .......................................................49 2.2.4 Corrosion of Metals ...............................................................................................52 CHAPTER 3 METHODOLOGY AND PROCEDURES....................................................62 vii 3.1 Fatigue Crack Initiation and Growth ..........................................................................62 3.2 Electrochemical Fatigue Crack Treatment ................................................................. 72 3.3 Treated Crack Growth ..................................................................................................75 3.4 Scanning Electron Microscopy ................................................................................... 75 3.5 Optical Microscopy ...................................................................................................... 79 3.6 Energy-dispersive X-ray Spectroscopy .......................................................................80 3.7 Corrosion
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