Fatigue Life Prediction of High Strength Aluminum Alloy Conductor Wires with Rough Surface

doi:10.11900/0412.1961.2021.00049

Acta Metall Sin

2022, Vol. 58

Issue (8): 1035-1043 DOI: 10.11900/0412.1961.2021.00049

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Fatigue Life Prediction of High Strength Aluminum Alloy Conductor Wires with Rough Surface

SONG Wenshuo¹, SONG Zhuman², LUO Xuemei², ZHANG Guangping², ZHANG Bin¹(

)

^1.Key Laboratory for Anisotropy and Texture of Materials, Ministry of Education, School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
^2.Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Cite this article:

SONG Wenshuo, SONG Zhuman, LUO Xuemei, ZHANG Guangping, ZHANG Bin. Fatigue Life Prediction of High Strength Aluminum Alloy Conductor Wires with Rough Surface. Acta Metall Sin, 2022, 58(8): 1035-1043.

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Abstract

The power industry is changing from rapid growth to high-quality development, and there are urgent demands for the high-quality and high-service reliability of overhead lines. Al-Mg-Si alloys are widely used in the production of long-distance overhead lines owing to their high strength-to-density ratio, good conductivity, and corrosion resistance. In the overhead line service, surface defects reduce their mechanical properties, and surface roughness greatly affects its fatigue properties. A single-strand conductor of 6101 aluminum alloy was employed to investigate the fatigue properties of the conductors with different roughness. The fatigue strength of the alloy wires decreased gradually with an increase in the surface roughness (maximum height of profile, R_z). As R_zincreased from 57.9 to 161.7 μm, the fatigue limit decreased by ~36.4%. The result indicates that an increase of R_z increases the theoretical stress concentration factor $K t$ , which facilitates the initiation of fatigue cracks, and the fatigue strength decreases accordingly. Furthermore, the surface roughness is equivalent to the size of the initial crack $a 0$ = $π L R z 2$ (L is the average value of the arerage width of profile element). A model suitable for predicting the fatigue life of conductors with different surface roughness was obtained.

Key words: aluminum alloy conductor surface roughness stress concentration fatigue life

Received: 28 January 2021

ZTFLH:

TB31

Fund: National Natural Science Foundation of China(51671050);National Natural Science Foundation of China(51971060)

About author: ZHANG Bin, professor, Tel: (024)83691585, E-mail: zhangb@atm.neu.edu.cn

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	Wenshuo SONG
	Zhuman SONG
	Xuemei LUO
	Guangping ZHANG
	Bin ZHANG

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https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00049 OR https://www.ams.org.cn/EN/Y2022/V58/I8/1035

Fig.1 Schematic of specimen dimension for fatigue testing (R_a—arithmetical mean deviation of the profile; unit: mm)

Fig.2 TEM image of the cross-section (a) and STEM image of the longitudinal section (b) of microstructure of the 6061 aluminum alloy conductor wire specimen, and EDS element maps of the framed area in Fig.2b (c, d)

Fig.3 Surface morphologies and surface profile curves of 6061 aluminum alloy conductor wire specimens with different roughnesses (L'—length of the statistical rough surface, R_z—the maximum height of the profile)
(a) R_z = 161.7 μm (b) R_z= 148.9 μm (c) R_z= 104.0 μm (d) R_z = 57.9 μm

Table 1 Surface roughness parameters of the 6061 aluminum alloy conductor wire specimens

Fig.4 Stress amplitude-fatigue life (S-N) curves of 6061 aluminum alloy conductor wire specimens with different surface roughness (The arrow indicates that the sample is not failure under this stress amplitude and cycle)

Fig.5 SEM images of fracture surfaces of the 6061 aluminum alloy conductor wire specimens with different roughnesses
(a) R_z= 161.7 μm (b) local enlarged image of the selected area in Fig.5a (c) R_z= 57.9 μm
(d) local enlarged image of the selected area in Fig.5c (Frames in Fig.5d show the fatigue crack sources)

Fig.6 Relationship of stress amplitude and R_z and corresponding fracture morphologies (insets) of 6061 aluminum alloy conductor wire specimens with different roughnesses
(a) 10⁴~10⁵ cyc (b) 10⁵~10⁶ cyc

Fig.7 Fatigue fracture expansion areas corresponding to different roughnesses (The yellow areas are expansion areas, and green areas are instantaneous fracture areas)

Fig.8 Stress distributions at the notch with R_z = 57.9 μm (a), R_z = 104.0 μm (b), R_z= 148.9 μm (c), R_z= 161.7 μm (d), and schematic illustration of equivalent notch (e) (L is the average value of the average width of profile element)

Table 2 The theoretical stress concentration factor calculated by simulation

Fig.9 Theoretical stress concentration factors corresponding to different R_z values

Fig.10 Fatigue limit range corresponding to different crack sizes (g—slope of curve, a_sc—critical crack size)

Fig.11 Comparisons of calculation results and experimental results
(a) R_z= 57.9 μm (b) R_z= 104.0 μm (c) R_z= 148.9 μm (d) R_z= 161.7 μm

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