Journal of Materials Processing Technology 210 (2010)
11971202
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Effect of pitting corrosion on fatigue performance of
shot-peened aluminium alloy 7075-T651U. Zupanc a , J. Grum b,a
b
Welding Institute, Ptujska 19, SI-1000 Ljubljana, Slovenia
University of Ljubljana, Faculty of Mechanical Engineering, Aker
eva 6, SI-1000 Ljubljana, Slovenia s c
a r t i c l e
i n f o
a b s t r a c tPitting corrosion has a major inuence on aging of
structural elements made of high-strength aluminium alloys as
corrosion pits lead to earlier fatigue crack initiation under
tensile dynamic loading. A cause of fatigue crack initiation in a
corrosive medium is a stress concentration at a corroded area. In
order to improve material resistance to corrosion fatigue it is
necessary to reduce pit-tip stresses. To eliminate or reduce pit
stresses, cold surface hardening by shot peening was proposed. The
objective of the present study was to investigate the effect of
surface hardening by shot peening on electrochemical stability and
corrosion fatigue properties of high-strength aluminium alloy
7075-T651 in the corrosive environment of a chloride solution. The
results obtained show a favourable inuence of shot-peening
treatment on corrosion fatigue properties. Induced compressive
residual stresses in the surface layer retard the initiation of
fatigue cracks, and so the fatigue life improvement of structural
elements made of high-strength aluminium alloys was observed. 2010
Elsevier B.V. All rights reserved.
Article history: Received 20 October 2009 Received in revised
form 5 February 2010 Accepted 4 March 2010
PACS: 46.50 62.20.Me 81.40.Np 81.40.Ef Keywords: Aluminium
alloys Pitting corrosion Fatigue Crack initiation
1. Introduction Surface corrosion has a major inuence on aging
of structural elements made of high-strength aluminium alloys.
Aluminium alloy 7075 in alloy system AlZnMgCu contains a high
number of intermetallic particles, i.e. constituent particles,
where heterogeneity of a microstructure has an essential inuence on
corrosion properties. Birbilis et al. (2006) electrochemically
analysed isolated constituent particles of 7075 aluminium alloy.
Large constituent particles Al7 Cu2 Fe, Al23 CuFe4 , and Al2 CuMg
had different electrochemical potential compared to the aluminium
matrix. Due to electrochemical reactions in a corrosive
environment, dissolved corroded areas lead to earlier fatigue crack
initiation. Numerous studies relate corrosion surface damage to
reduced material strength under dynamic loading. Pao et al. (2000)
reported on the formation of fatigue cracks at corrosion pits on
aluminium 7075-T7351. A decrease in the fatigue crack initiation
threshold by 50% in axial fatigue testing was observed. Genel
(2007) stated a degradation of the fatigue strength limit at 107
cycles by 60% of aluminium 7075-T6. Wang et al. (2003) investigated
the effect
Corresponding author. Tel.: +386 1 2809 442; fax: +386 1 2809
422. E-mail addresses: uros.zupanc@i-var.si (U. Zupanc),
janez.grum@fs.uni-lj.si (J. Grum). 0924-0136/$ see front matter
2010 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2010.03.004
of pitting in high-cycle fatigue testing upto 108 cycles, where
a decrease of the threshold stress intensity by about 20% was
observed. DuQuesnay et al. (2003) stated that the depth of
corrosion pits is the most important factor affecting a
fatigue-exposed material. With longer exposure to a corrosive
environment the pit depth increases. Jones and Hoeppner (2005)
experimented a critical pit depth for fatigue crack initiation
measuring between 40 and 60 m. Furthermore, subsurface pit growth
or tunnelling was reported. A cause of fatigue crack initiation in
a corrosive medium is a stress concentration at pit locations.
Sankaran et al. (2001) related a pit depth and crack growth rate
under dynamic loading to a stress intensity factor K at aluminium
7075-T6 using AFGROW software. Pidaparti and Patel (2008), using
FEM, made an analysis of local tensile stress environment around
pits at aluminium 2024-T3. Stress levels at a pit area are in the
magnitude of material plane strain fracture toughness, from which
it is possible to estimate fatigue crack initiation. In order to
improve material resistance to corrosion fatigue it is necessary to
reduce pit-tip stresses in the corroded areas. Shot peening (SP) as
intense plastic deformation in a thin surface layer affects fatigue
properties by inducing favourable compressive residual stresses.
Sharp and Clark (2001) showed that SP-treated specimens increased
material resistance to crack initiation. Peening improved fatigue
life by a factor of 1.26 depending on choosing
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210 (2010) 11971202
the surface to pitting corrosion, the specimens were rotated
every 24 h during the test.
2.4. Surface integrity characterizationFig. 1. Fatigue specimen
details and dimensions (in mm).
different rework specications. Rodopoulos et al. (2004)
indicated improved fatigue life of peened aluminium 2024-T351 by
about 90% in axially fatigue testing. Benedetti et al. (2009)
improved fatigue strength on aluminium 7075-T651 in reverse bending
mode at 5 million cycles upto 46% by SP treatment. In the present
research series of tests were performed to analyze the effects of
SP treatment on surface corrosion properties. The objective of the
study was to investigate the effect of SP treatment on
electrochemical stability and corrosion fatigue properties of
high-strength aluminium alloy 7075-T651 in chloride environments.
Fatigue behaviour of prior-corroded as-machined and SP-treated
specimens was evaluated to quantify the fatigue life changes.
Characterization of the surface corrosion degradation and
evaluation of pit-to-crack transition on fatigued specimens were
made. Additionally, electrochemical tests in a chloride solution
were conducted to investigate the effect of SP on surface corrosion
properties. 2. Experimental details 2.1. Material A wrought plate
of high-strength aluminium alloy 7075-T651 of 20 mm in thickness
was delivered with the chemical composition (in wt.%):
Al5.78Zn2.56Mg1.62Cu 0.21Cr0.05Mn0.04Ti0.09Si0.18Fe. Static
mechanical properties of the tested material were: Rm = 585 MPa,
Rp02 = 532 MPa and A50 = 12%. Specimens for fatigue testing were
prepared in a long traverse (LT) direction (Fig. 1). As-machined
specimens were ultrasonically cleaned in ethanol. In research the
prepared specimens were evaluated in four different research
combinations: (a) as-machined (AM); (b) as-machined and corroded
(AM & Corr); (c) shot-peened (SP); and (d) shot-peened and
corroded (SP & Corr). 2.2. Shot peening The specimens were
SP-treated from all sides at the Metal Improvement Company in
Germany using an air-blast machine. Cast steel-shot MI-170H with
hardness of 55 HRC and a nominal diameter of 0.40 mm was chosen. In
order to avoid medium collision, the angle of nozzle inclination
was shifted by 5 with regard to the vertical axis. A constant
specimen distance from the nozzle of around 120 mm was maintained.
Surface coverage was set to 150%. Comparative Almen intensity value
of 12A was achieved. 2.3. Salt spray tests The specimens for
fatigue testing were placed in a salt spray chamber for surface
corrosion tests in accordance with ASTM B117 for 168 h (7 days).
Before the corrosion process, the SP-treated specimens were cleaned
with concentrated HNO3 acid to avoid surface contamination by
possible steel-shot residues. The prepared solution had a pH value
of 6.5 and the inner chamber temperature was set to 35 C. Specimens
were placed individually, parallel to each other, on plastic
supports at an angle of indentation of 20 with regard to the
vertical axis. In order to provide uniform exposure of
After the exposure of the specimens in the salt spray chamber,
the specimen surface was covered with white corrosion products
consisting mostly of Al(OH)3 . For the analysis of surface
roughness and assessment of the pit size at the surface, the
corrosion products were cleaned with a hard polymer wire brush in a
water-diluted nitric acid (10% HNO3 ) at room temperature. The
evaluation of the tested specimens comprised surface properties and
residual-stress measurement in the thin hardened layer. Measurement
of highresolution surface roughness was made with a Taylor Hubson
Form Talysurf Series 2 device. The residual-stress measurements
were made with a semi destructive hole-drilling method in
accordance with ASTM 837.
2.5. High-cycle fatigue testing Fatigue testing was carried out
without preliminary removal of the corrosion products from the
surface. Bending fatigue testing of the specimens was carried out
with a Rumul Cracktronic device at room temperature. A constant
amplitude bending stress was applied in the range of the maximum
applied stresses, i.e. those ranging between 15% and 65% of
delivered-material tensile strength Rm. The testing resonant stress
frequency was 107 Hz using a sinusoidal waveform at a stress ratio
R of 0.05. A criterion of specimen failure was a drop of inherent
oscillation by more than 3%, where fatigue cracks occurred in a
depth of upto 4 mm. In the present study a run-out criterion as a
limit of fatigue strength was set at 10 million cycles. Fractured
surfaces of all fatigued specimen were further evaluated using a
scanning electron microscope (SEM).
2.6. Electrochemical testing Electrochemical potentiodynamic
testing was conducted in a 0.1 M NaCl solution, made from
analytical grade chemical and distilled water. The pH value was
6.5. For electrochemical testing additional as-machined and
SP-treated specimens were sectioned in the form of discs of 15 mm
in diameter in the longitudinal (L) direction. A Gamry
Potentiostat/Galvanostat PC3 with a three-electrode corrosion cell
was used, with the working electrode embedded in a Teon holder. The
exposed area measured 0.785 cm2 . A saturated calomel electrode
(SCE) served as a reference electrode and two stainless-steel rods
as counter electrodes. Following a 1-h stabilization at open
circuit potential (OCP), measurements were performed in the
following order: linear polarisation, 10 mV vs. OCP, using a scan
rate of 0.1 mV/s and potentiodynamic curves, starting from 250 mV
vs. OCP upto 1 V using a scan rate of 1 mV/s. All potentials are
reported with respect to SCE scale. Prior to potentiodynamic
measurements electrochemical impedance spectroscopy (EIS)
measurements were done with a perturbation signal of 10 mV (10
points per decade) in the frequency range from 65 kHz to 5 mHz.
3. Results and discussion The results of the surface integrity
analysis, residual-stress measurement, fatigue testing with post
fatigue fractographic analysis, and electrochemical testing are
presented in following sections.
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210 (2010) 11971202
1199
Fig. 2. SEM images of corroded as-machined (left) and SP-treated
material (right). The pits analysed are marked with an arrow.
3.1. Surface integrity analysis SP treatment and pitting
corrosion of tested specimens essentially changed the surface
roughness properties. Results of the measurement of arithmetic
average (Ra) and root mean square (Rq) surface roughness after SP
treatment and the exposure in the salt chamber are given in Table
1. Reference surface roughness of the asmachined specimens is a
result of nal grinding with emery paper of granulation of upto
1000. The as-machined specimens exposed to corrosion in the salt
chamber essentially increased roughness by four times due to the
surface corrosion damage (see Table 1). The size and shape of the
corrosion pits formed at the asmachined and SP-treated specimens
was evaluated. Surface SEM images are shown in Fig. 2. The pits
were lined up in the rolling direction in agreement with local
dissolution zones at constituent particles. The dimension along the
rolling direction was designated as the pit length and
perpendicular to rolling direction designated as the pit width. The
pit lengths at the as-machined and corroded material measured in
length upto 500 m and in width to 1040 m (Fig. 2a). Separate local
pits combined in elongated corroded lines at the area of local
dissolution. Furthermore, the corrosion pits grew not only in the
rolling direction but did also coalescent with the pits in the
direction perpendicular to rolling. Approximately 15 pits/mm2 at
the corroded surfaces with a depth greater than 25 m were found.
Maximal individual pit depths amounted to upto 45 m. Surface
roughness changes at the SP-treated specimens were affected by the
absorbed medium kinetic energy. The typical diameter of the dimples
ranged between 150 and 200 m. Subsequent salt spray exposure of the
peened specimens increased the surface roughness by 10%. The pits
at the SP-treated specimens were not oriented with regard to the
rolling direction as observed at the ground as-machined specimens
(Fig. 2b). This can be contributed to local plastic deformation of
the constituent particles in the peened surface layer. After SP
treatment the number and size of pits at the surface decreased
perceptibly. The SP-treated specimens exposed to the corrosive
environment contained fewer surface pits. An average corrosion pit
length at the SP-treated specimens measured upto 100 m, and their
width upto 3050 m. The pit density
at the surface was essentially smaller and amounted to around 57
pits/1 mm2 . Due to surface roughness measuring machine limitations
and the fact that pits can be much larger beneath the surface as
observed on the surface, the true pit dimensions were evaluated
further in the post fatigue fractographic analysis. However, some
individual pit depths of the SP-treated material measured upto 60
m. The experimental results of surface pit properties are
comparable to those found in other authors studies on heat-treated
high-strength aluminium alloys. Curtis et al. (2003) observed less
but deeper pits on shot-penned aluminium 2024. On the contrary,
Prevey and Cammett (2004) reported shallower pits by one-third on
low plasticity burnished aluminium 7075 compared to as-machined
material. Trdan et al. (2009) concluded lower pit density on laser
shock-processed 6xxx series aluminium alloys. All heat-treated
aluminium alloys had induced compressive residual stresses by using
different surface treatment techniques. 3.2. Residual stresses
Residual stresses are one of key inuences on material fatigue
resistance, also in a corrosive environment. Fig. 3 shows the
measured residual stresses as a function of depth. Prior to SP
treatment the as-machined specimens showed residual stresses in the
thin surface layer amounting to around 50 MPa, induced most
probably due to the specimen preparation. Relatively
small-magnitude measured stress of the as-machined specimens was
neglected in further evaluation. The residual compressive stresses
after SP treatment amounted to around 320 MPa, i.e., to nearly 55%
of the ultimate tensile strength of the material delivered. Depths
of the
Table 1 Surface roughness measurement results. Treatment Ra ( m)
Rq ( m) AM 0.32 0.47 AM & Corr. 1.24 2.02 SP 5.81 7.09 SP and
Corr. 6.27 7.81
Fig. 3. Distribution of residual stresses vs. depth for
7075-T651 aluminium.
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210 (2010) 11971202
Fig. 4. Corrosion fatigue life for 7075-T651 aluminium.
induced residual stresses after SP treatment of upto 500 m are
greater than the depth of typical corrosion pits; therefore,
residual stresses should inuence local stress concentrations at the
pit area in fatigue testing. Due to the surface corrosion pits at
the SP-treated specimens a relief of residual stresses was
observed. Relaxation of the residual stresses at the surface
amounted to around 23% of the residual stresses after SP treatment.
No signicant changes in residual-stress measurement of the
as-machined and corroded specimens were noticed. 3.3. Bending
fatigue testing The semi-logarithmic SN curves generated for the
fatigued specimens in different research combinations are shown in
Fig. 4. Fatigue results for the as-machined specimens presented a
baseline for further comparison of fatigue properties. As the tests
were limited in the number of specimens and the applied fatigue
load
cycles of upto 107 cycles, a more accurate fatigue endurance
limit at applied stresses in a range of 5 108 or even in a range of
109 cycles cannot be conrmed without additional testing. The
presence of a corrosive chloride environment has a major inuence on
fatigue properties of high-strength aluminium alloy 7075. Low
material corrosion resistance signicantly decreased the fatigue
life of the corroded specimens. The fatigue life at higher applied
stresses decreased by a factor of about 10 compared to the
baseline. The fatigue stress limit of the corroded specimens of 85
MPa at 107 cycles amounted to only 45% of the fatigue stress limit
of the baseline at 189 MPa. Local stress concentrations at the
degraded area resulted in much faster fatigue crack initiation. The
fractured surfaces were examined to evaluate critical pit(s) for
fatigue crack initiation. Two typical fractured surfaces of the
corroded as-machined specimens are shown in Fig. 5. A fatigue crack
mainly nucleated from an individual pit at higher applied stresses
(Fig. 5a). The critical pit depth of the specimens fatigued at 143
MPa was around 110 m. At lower fatigue stresses two or more
crack-nucleating pits were found. A minimal critical pit depth to
initiate a fatigue crack at the as-machined polished specimen was
around 70 m (Fig. 5b). A favourable inuence of SP treatment on
material fatigue resistance was found. SP treatment nearly doubled
the maximal cycles to failure at the higher applied stresses when
compared to the untreated specimens. The fatigue limit of the
SP-treated specimens increased to 218 MPa at 107 cycles.
Furthermore, the SP-treated specimens outperformed the as-machined
parent material when exposed to corrosive chloride environment by a
factor of 2. The fatigue stress limit increased to 165 MPa. The
experimental data assumed an increase of fatigue strength of the
SP-treated material due to the compressive residual-stress ability
to inuence crack nucleation. Strain hardening by shot peening
retarded the crack propagation. Increased resistance to plastic
deformation and the residual-stress prole so provided a
corresponding fatigue crack
Fig. 5. Fractured surface of fatigued corroded as-machined
specimen from individual pit (left) and multiple pits-to-crack
nucleation (right). The critical pits are marked with a dotted
line.
Fig. 6. Fractured surface of fatigued SP-treated specimens
(left) and also in corrosive conditions (right). The crack
initiation sites are marked with an arrow.
U. Zupanc, J. Grum / Journal of Materials Processing Technology
210 (2010) 11971202
1201
Fig. 7. Corroded specimen cross-sections analysis of fatigue
cracks formed from pits.
closure. The induced compressive residual stresses also retarded
fatigue crack initiation in the pit area that resulted in better
fatigue properties. Fatigue crack initiation was observed at much
greater depths in the SP-treated specimens than in the as-machined
specimens. The SEM images of fractured surfaces of the SP-treated
specimens are shown in Fig. 6. Typical initiation depths were found
upto 370 m below the surface, depending on maximal applied fatigue
stresses, whereas with the as-machined specimens initiation was, at
maximum, at 100 m beneath the surface. The compressive
residual-stress layer pushed the crack region beneath the surface.
Fatigue cracks of the corrosion-exposed SP-treated specimens showed
the same behaviour. Cracks also initiated at sub-supercial sites.
Even at a highly corroded area at the edge of the corroded
SP-treated specimen a fatigue crack was observed at 246 m beneath
the surface (Fig. 6b). In the surface integrity analysis and
further in the fatigue performance evaluation, pitting corrosion
was dened as a type of corrosion damage. But to characterize a true
corrosion nature, corresponding cross-sectional microstructural
images of fatigue specimens were studied. They are shown in Fig. 7.
The crosssections were polished and etched using Kellers reagent.
Multiple fatigue cracks initiated from a highly degraded surface of
the asmachined specimen fatigued at 110 MPa (Fig. 7a). Individual
surface layers of exposed microstructural grain bodies were
entirely corroded due to an intergranular corrosion attack. The
corrosive attack was oriented in agreement with local dissolution
zones of the constituent particles lined in the LT direction. A
fatigued SP-treated and corroded specimen is shown in Fig. 7b where
crack initiated at the surface dimple. A residue of aluminium
hydroxide Al(OH)3
Table 2 Corrosion current densities. Treatment jcorr (A/cm
)2
As-machined 2.1 106
Shot-peened 5.2 106
Ratio 1:2.5
at the surface and secondary fatigue crack propagation were also
visible. 3.4. Electrochemical testing Electrochemical
potentiodynamic testing was conducted to investigate effects of SP
treatment on the material electrochemical characteristics.
Different electrochemical properties were evaluated: corrosion
potential, corrosion current density, and corrosion rate.
Potentiodynamic polarisation curves and electrochemical impedance
properties are shown in Fig. 8. Results show nearly the same free
corrosion potential (Ecorr ) of the as-machined and the SP-treated
specimens with values near 700 mV (Fig. 8a). A comparison of the
corrosion current densities (Icorr ) was performed with a Tafel
analysis. The average values of ve individual tests for corrosion
current densities are given in Table 2. Higher corrosion current
density (Icorr ) on the SP-treated specimens by a factor of 2.5
with reference to the as-machined specimens was observed. The
increase of corrosion current density indicated a higher pit growth
rate. The increased surface roughness of the SP-treated specimens
and possible remains of the steel medium at the aluminium surface
could have inuenced the electrochemical properties although the
treated surface was chemically
Fig. 8. Polarisation curves of as-machined and SP-treated
specimens in 0.1 M NaCl (a). Electrochemical impedance spectroscopy
results shown as Bode plots (b).
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210 (2010) 11971202
cleaned. Electrochemical impedance data show similar corrosion
susceptibility. The polarisation resistance (Rp ) is estimated from
the impedance response in the Bode plot as a total impedance value
at the peak of the curve (Fig. 8b). The SP-treated material had a
lower Rp . The evaluated Rp was 4.3 k cm2 for the asmachined
material, while the value for the SP-treated specimens was 3.4 k
cm2 . The decrease of impedance response at lower frequencies
refers to a dissolution process of the tested aluminium surfaces in
the chloride solution. Overall, both surfaces are corrosion
susceptible, but the SP-treated specimens showed slightly lower
polarisation resistance. Curtis et al. (2003) observed similar
detrimental higher corrosion current density of the SP-treated
aluminium 2024. An increase in corrosion current density by a
factor of 5 was reported. The specimens were electrochemically
tested in the same microstructural L direction as in present
research. Liu and Frankel, 2006 showed the same effect of
increasing corrosion current density in low plasticity burnished
aluminium 7075, experimented in an isolated longitudinal (L)
direction. But the results obtained in the short traverse (ST)
directions were in a contrast where the corrosion current density
decreased by a factor of about 3. To estimate the real fatigue life
improvement of the peened material it is important to evaluate the
benecial compressive residual-stress eld compared to critical pit
depths on the one hand and the possible detrimental electrochemical
changes on the other hand. Future work will combine effects of
crack-nucleating pits, induced compressive residual-stress proles,
and electrochemical potentiodynamic properties of SP-treated
material in all three material microstructural planes. Complex
interactions between residual-stress distribution, microstructure
orientation, and grain sizes in different microstructural
directions are expected. Development of such a probabilistic model
is under investigation to understand these phenomena and predict
structural integrity of elements made of high-strength aluminium
alloys in a corrosive environment. 4. Conclusions To determine the
effects of pitting corrosion on the fatigue properties of the
SP-treated aluminium alloy 7075-T651, a series of tests were
performed. The research results demonstrate positive effect of the
SP treatment of structural elements exposed to the corrosive
chloride environment. Based on the study of the inuence of the SP
treatment on corrosion fatigue resistance of aluminium alloy
7075-T651 in the 5% NaCl solution fog chamber and in 0.1 M NaCl
solution, following conclusions can be drawn: Fatigue resistance of
the corroded specimens drastically decreased in comparison with the
parent material due to material pitting corrosion. A decrease of
fatigue life by a factor of 10 was observed with individual fatigue
stresses. The fatigue stress limit of the as-machined and corroded
specimens of 85 MPa amounted
to only 45% of the fatigue stress limit of the parent material
at 189 MPa. Local stress concentrations at the degraded surface
pits area resulted in much faster fatigue crack initiation. After
the SP treatment the number of surface pits was considerably
reduced. The SP-treated specimens outperformed the parent material
when exposed to the corrosive chloride environment by a factor of
2. The fatigue stress limit of the corroded SP-treated specimens
increased to 165 MPa and thus approached 87% of the baseline
result. The experimental data assumed an increase of fatigue
strength of the peened material due to the residual-stress ability
to retard crack propagation. In electrochemical potentiodynamic
testing, corrosion current density higher by a factor of 2.5, with
reference to the as-machined material, was observed with the
SP-treated specimens. The increase of corrosion current density
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