Doctor of Philosophy, The Ohio State University, 2020, Materials Science and Engineering
Aluminum-magnesium (Al-Mg) alloys offer high strength-to-weight ratios, weldability, and excellent corrosion resistance in marine environments. However, the corrosion resistance of Al-Mg alloys with greater than 3 wt.% Mg degrades after long-term exposure to temperatures as low as 40 °C, a phenomenon called sensitization. Sensitization is caused by precipitation of β-phase (Al3Mg2) on α-Al grain boundaries. Grain boundary β precipitates are anodic to the α-Al matrix and increase susceptibility to intergranular corrosion, stress corrosion cracking (SCC), and corrosion fatigue. Until recently, a majority of corrosion fatigue tests were conducted at a high fatigue loading frequency (f) to estimate the effect of sensitization on corrosion fatigue crack growth rates (da/dN) during service. However, f in marine environments can be on the order of 0.01 Hz or lower. In this work, fracture mechanics-based experiments were utilized to understand the effects that f, sensitization level, and electrochemical potential have on corrosion fatigue da/dN of Al-Mg alloys used in marine environments.
In Chapter 2, corrosion fatigue da/dN were quantified for AA5456-H116 as a function of f and sensitization level when loaded under freely corroding conditions in 3.5 wt.% NaCl at a constant stress intensity range (ΔK) and load ratio (R). A critical sensitization level of 24 mg/cm2 was established at and above which da/dN was inversely dependent on f. Sensitization to 70 mg/cm2 accelerated da/dN by approximately 2× at 10 Hz and 5× at 0.03 Hz compared to rates for the as-received microstructure (5 mg/cm2). Below 24 mg/cm2, da/dN were not higher than for the as-received microstructure and were f independent. Three possible explanations for the inverse f dependence were discussed. This research demonstrated the risk of overestimating fatigue life of sensitized AA5456-H116 in marine environments should the f dependence of da/dN not be considered.
In Chapter 3, the interplay between SCC an (open full item for complete abstract)
Committee: Jenifer (Warner) Locke Ph.D. (Advisor); Gerald Frankel Ph.D. (Committee Member); Christopher Taylor Ph.D. (Committee Member); Eric Schindelholz Ph.D. (Committee Member)
Subjects: Engineering; Materials Science; Metallurgy