High-Cycle Fatigue Properties and Residual Stress Relaxation Mechanism of Micro-Arc Oxidation 6082-T6 Aluminum Alloy

doi:10.11900/0412.1961.2020.00528

Acta Metall Sin

2022, Vol. 58

Issue (3): 334-344 DOI: 10.11900/0412.1961.2020.00528

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High-Cycle Fatigue Properties and Residual Stress Relaxation Mechanism of Micro-Arc Oxidation 6082-T6 Aluminum Alloy

SU Kaixin¹, ZHANG Jiwang¹(

), ZHANG Yanbin², YAN Tao³, LI Hang¹, JI Dongdong¹

^1.State Key Laboratory of Traction Power, Southwest Jiaotong University, Chengdu 610031, China
^2.School of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, China
^3.Bj -baodeli Electrical Equipment Co. , Ltd. , Baoji 721000, China

Cite this article:

SU Kaixin, ZHANG Jiwang, ZHANG Yanbin, YAN Tao, LI Hang, JI Dongdong. High-Cycle Fatigue Properties and Residual Stress Relaxation Mechanism of Micro-Arc Oxidation 6082-T6 Aluminum Alloy. Acta Metall Sin, 2022, 58(3): 334-344.

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Abstract

Recently, the fatigue failure of aluminum alloy components of high-speed railway catenary is becoming increasingly serious, which causes a threat to the normal operation of high-speed trains. In this study, the effect of micro-arc oxidation (MAO) coating on the high-cycle fatigue properties of 6082-T6 aluminum alloy for the catenary cantilever of the high-speed railway was studied. First, the rotating bending fatigue tests of untreated (UP) and MAO specimens of 6082-T6 aluminum alloy were performed. Then, the surface morphology and roughness, cross-section morphology, nanoindentation hardness, and elastic modulus gradient distribution, phase composition of MAO coating, and fatigue fracture morphology of the fatigue samples were studied by a confocal laser microscope, nanoindentation, XRD, and SEM. The experimental results showed that after MAO treatment, a large number of micro-cracks and pores were formed on the surface of the samples, and the morphology of the samples severely deteriorated. The XRD results indicated that the closer the coating surface, the stronger was the diffraction peaks of α-Al₂O₃ and γ-Al₂O₃. Besides, there was the higher tensile residual stress at the coating-substrate interface, which led to a significant reduction in fatigue properties. The fatigue strength decreased by 26.7% at 2 × 10⁷ cyc. Finally, the formation and relaxation mechanisms of tensile residual stress under cyclic stress were analyzed using mismatch strain theory, and the effects of the coating on the fatigue properties of the substrate under high and low cyclic stresses were discussed further.

Key words: aluminum alloy micro-arc oxidation residual stress fatigue property

Received: 29 December 2020

ZTFLH:

TG174.4

Fund: National Natural Science Foundation of China(52075457)

About author: ZHANG Jiwang, Tel: (028)87600843, E-mail: zhangjiwang@swjtu.edu.cn

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	Kaixin SU
	Jiwang ZHANG
	Yanbin ZHANG
	Tao YAN
	Hang LI
	Dongdong JI

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https://www.ams.org.cn/EN/10.11900/0412.1961.2020.00528 OR https://www.ams.org.cn/EN/Y2022/V58/I3/334

Fig.1 Sample shape and dimensions for mechanical property (a) and fatigue property (b) tests (unit: mm)

Fig.2 Schematic of residual stress measurement

Table 1 Mechanical properties of untreated (UP) and micro-arc oxidation (MAO) 6082-T6 Al alloy

Fig.3 Surface morphologies (a, c) and 3D profiles (b, d) of UP (a, b) and MAO (c, d) samples (Inset in Fig.3c shows a higher magnification for MAO surface morphology)

Table 2 Surface roughnesses of UP and MAO samples

Fig.4 XRD spectra of the MAO coating surface (a) and interior (b)

Fig.5 Cross section morphologies of UP (a) and MAO (b) samples

Fig.6 Coating hardness and elastic modulus distributions

Fig.7 Stress-fatigue life (S-N) curves of UP and MAO samples

Fig.8 Fracture morphologies of UP and MAO samples

Fig.9 Relaxation of tensile residual stress under different cyclic stresses of MAO samples

Fig.10 Formation (a) and relaxation (b) of tensile residual stress at the MAO coating-substrate interface

Fig.11 The variation trend of fatigue life of MAO sample compared with UP sample under different cyclic stresses (β—percentage of fatigue life change)

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