Fatigue Mechanis

Crack grows incrementally

da m = ( K ) dN

typ. 1 to 6

~ ( ) a

Failed rotating shaft

increase in crack length per loading cycle crack origin

--crack grew even though Kmax < Kc --crack grows faster as

increases crack gets longer loading freq. increases.

Fatigue (esign )ara eters

Fatigue li it! Sfat"
--no fatigue if S < Sfat
Sfat safe 1+ , 1+ 1+ . 1+ % N * Cycles to failure
#dapted fro Fig. $.1%&a'! Callister 7e.

S * stress a plitude unsafe

case for steel &typ.'

/o eti es! the fatigue li it is 0ero1

S * stress a plitude unsafe safe 1+ , 1+ 1+ . 1+ % N * Cycles to failure

case for #l &typ.'

#dapted fro Fig. $.1%&2'! Callister 7e.

3 proving Fatigue 4ife

1. 3 pose a co pressive surface stress
&to suppress surface cracks fro growing'
m
/ * stress a plitude
#dapted fro Fig. $.68! Callister 7e.

3ncreasing

near 0ero or co pressive m oderate tensile m 4arger tensile m 5 * Cycles to failure

--Method 1" shot peening

shot put surface into co pression

--Method 6" car2uri0ing

C-rich gas

6. 7e ove stress concentrators.

2ad 2ad

2etter 2etter
#dapted fro Fig. $.6-! Callister 7e.

FAE CG/F GF CG77G/3G5

Corrosion"
-- the destructive electroche ical attack of a -- #l Capone9s
ship! /apona! off the coast of :i ini.
)hotos courtesy 4.M. Maestas! /andia 5ational 4a2s. Bsed with per ission.

aterial.

Cost"
-- 8 to -; of the <ross 5ational )roduct &<5)'= -- this a ounts to >ust over ?8++ 2illion@yr==

= A.A. Bhlig and C.7. 7evie! Corrosion and Corrosion Control: An Introduction to
Corrosion Science and Engineering ! ,rd ed.! Dohn Ciley and /ons! 3nc.! 1%$-.

==Econo ic 7eport of the )resident &1%%$'.

Chat is CG77G/3G5H
Corrosion is a natural event
It represents a return of metals to their more natural state as minerals (oxides)

Metal ICantsJ to 2e (irt

ENERGY
ORE

METAL

:asics of Corrosion
Corrosion is essentially the oxidation of metal

Source: Moore, . . Chemical Metallurgy

Need: 1. 6. ,. 8.

#n #node &where oKidation is taking place' # Cathode &where reduction is taking place' Conductive electrolyte Electrical contact 2etween the #node and Cathode

Electroche istry

Corrosion is an electrochemical reaction

reaction at the anode: !+ + e"cid #olutions:

Mn+ + ne-

Possible reactions at the cathode: ! ! + $!$!! $ + e-

$ + !+ + e

Important thing to note is the flow of electrons

Fher odyna ic (riving Force

%i&e all chemical reactions 'hermod(namics )hat is the drivin* force for the reaction+ (other,ise stated as ,hat is the electrochemical potential for the reaction)
-issimilar metals -ifferent cold ,or& states -ifferent *rain si.es -ifference in local chemistr( -ifference in the availabilit( of species for a reaction (concentration cells) -ifferential aeration cells

(erivation of 5ernst Equation

a products G = G + RT ln(Q) = G + RT ln a reac tan ts
o o

/or:

Fe Fe + 2e

2+

2 H + + 2e H 2 ( g )
Fe + 2 H + Fe 2+ + H 2( g )
0
2+ 2+ a ( Fe ) f ( H ) [ Fe ] o o 2 G = G + ln = G + ln [ H + ]2 a ( Fe) a ( H + ) 2

(erivation of 5ernst EquationL

Introduce: 'he total electropotential is

1 2 -n/3
)here: / 2 /arada(4s constant (total char*e on "vo*adro4s number of electrons) n 2 the number of electrons transferred 3 2 'he electrode potential

nFE = nFE + RT ln(Q)

o

or nFE = nFE RT ln(Q)

o

Fher odyna ics Continued

5ernst 36uation:

RT E=E ln(Q) nF
o

'!3 7asic e6uation ,hich describes "%% corrosion reactions /or $ur 3xample:
2+ RT [ Fe ] o E=E ln + 2 nF [ H ]

5ote: p! 2 -lo*089!+:

)our2aiK (iagra
Potential vs p! p! is the measure of 9!+: ions in solution Map re*ions of thermod(namic stabilit( for metal4s a6ueous chemical species

Source: !!!.corrosionsource.com

/F#5(#7( EMF /E73E/

EMF series
etal #u Cu )2 /n 5i Co Cd Fe Cr Mn #l Mg 5a N O1.86+ P O+.,8+ - +.166 - +.1,6 - +.6-+ " o * - +.6.. +.1-,P - +.8+, - +.88+ - +..88 - +..6, - 1.666 - 6.,6, - 6..18 - 6.%68 " oetal

Metal with s aller

"ometal corrodes.

ore cathodic

EK" Cd-5i cell

Cd

6-QC

5i

ore anodic

1.+ M 1.+ M Cd 6O solution 5i 6O solution

<alvanic /eries
AB5F35<FG5 C3FR C#FE7! 6-C
Polts" /aturated Calo el Aalf-Cell 7eference Electrode
-1.1 -1.6 -1., -1.8 -1.6 -1.. -+., -+.. -+.1 -+.6 -+.8 -+.-+.6 O+.8 O+., O+.6 O+.1 -+.$ -+.% -1.+ -1.$ -1.+
Magnesiu

Cast 3ron #lu inu #lu inu #lloy -+-6 Mild /teel

Manganese Minc

Fin 4ead 5ickel - /ilver Copper #lloy 6+C2, #lloy 1$-1$-6 :rass #lloys #lloy ,7E6+ .+ - ,+ Copper-5ickel %+ - 1+ Copper-5ickel #lloy EFE66 :ron0e #lloys #lloy 6S #lloy 1.-8)A #lloy 6-- &ferralliu ' #lloy 6,+ &Coronel' #lloy 66-1! 66-1 - 1@8 #lloys C6.6! <! S #lloy 6-8 /4S MG5E4 alloys 8++! 78+-! N-++ #lloy :! )! )( &3lliu ' 35CG4GR alloy $++! $6-! $8+ 5ickel 6++! 6.+ /tainless /teel ,+8! ,16! ,1.! 8+, 35CG5E4 alloys 6++! 61.! 61$! 66-! 6.1! 6%+! .+6! S.-+ Fitaniu #lloy .++ &Dessop' O+.68 - +..6P )latinu

Source: Crum and Scar#erry, Corrosion of Nic$el %ase Alloys Conference &roceedings ' ASM ()*+

Ninetics (escri2es 7ate of 7eaction EvanTs (iagra

0.1 0.0

0 A

iofor H2 on Fe
2H

2H H2
+

+2e

IC OD N A

POTENTIAL VOLTS (SHE)

+2

-0.1 -0.2 -0.3 -0.4 -0.5 -0.6 -0.7 10 -10

eH
2

O H AT C

IC D

E CORR
Fe
+2 +2e

0 B

e io Fe F

IC OD N A

+2

B
-

i CORR

O H Fe AT C
10 -9 10 -8

CURRENT DENSITY, A/cm

e +2

IC D
10 -7

Fe
10 -6 10 -5 10 -4 10 -3 10 -2

#rea Effects
Aa * #rea 3nside Crevice &#nodic' Ac * #rea Gutside Crevice &Cathodic' Aa ,, Ac
M M
+

io H Aa
+

io H + A c

+e

io O Aa
2

O2 /OH +

ia O Ac
2

+H

O+

2e -

E M/M

2OH -

Crevice Effect No Crevice Effect

icorr in very aggresive environment

PLUS Crevice Effect

Log i

Effect of GKidi0er Concentration &e.g.! GKygen' on the Electroche ical :ehavior of an #ctive - )assive Metal

3ncreasing GKidant Concentration

M+

Log i
[ ontanna and Greene! Corrosion Engineering! M"Gra#$%ill! &'()*

Effect of Fe perature and (issolved G6

35 30 CORROSION RATE (MPY)) 25 20 15 10 5 0

V olts:Sa turaed Calome lHaf-C elRf renc Electrod CadmiAlu umin4c(a'es (a'nesium (<CA Aloy2-)"C:erHi'h&ut95a#E0!nS no2-);0567eraliumd 8 %*.-)#ic$elra9C<5Aoy=n Silver)3-0:H1RE2.+on?AysC#c$>a" el5.#i- .Cr Aloy2Cast9rn#i-ReS3.1 2Co:er-#ic$l50S@.st1!6n8 "1)25 1)3 Aloy3.6#ic$e2(<E5G@9C>*0 Ceso:8aly0."6HA%&9i+253 .0"5RBum82)* 5.32"0+@ 5. =ita niumStalesA9#C< Aloy2@SiverG9#C<5>a01.Es)3 "2)+E5y. -./0 -./0+V&latin um *21 05r) CrumG andScr!lvi ery"CosiS- onceCf#i$ traedHl%sAoy ydrochlsCnfe e&rocdinA 's-AS(at25C )*+5,

0 0

1 07

2 14

3 21

-./0 -./12 ) .-/)2 -./10 /5 -./23 /+ -./*) )/ -)/21 -)/052 -)/3+

DISSOLVED O2 (PPM)
35 42

7 49

8 56

9 63

10 70

11 77

28

LE!END "RESH #ATER $ 50%" "RESH #ATER $ 90%" "RESH #ATER $ 120%" VELOCITY & 2 5 "PS 'H& 7( R& 100M)0HM 'H& 7( R& 2500M)0HM

DISSOLVED O2 (Mg /

H2O)

Fypes of #queous Corrosion Cells

1eneral Corrosion %ocali.ed Corrosion Pittin* Crevice Corrosion ;nder-deposit Corrosion MIC 'uberculation 1alvanic Corrosion

<eneral Corrosion

<eneral Corrosion
O O M
*

+) +) +) +)

M* O OH) M* O M*

O OH M
*

+) +) +) +) +)

<andom Creation and -estruction of "nodes and Cathodes Movement of "nodes and Cathodes 5ear ;niform 'hinnin* )ei*ht %oss is a ;seful Measure

Source: Corrosion, ASM Handbook, Volume 1 , 1!"#

<eneral Corrosion
Griginal /urface

)enetration due to Corrosion

4ocali0ed Corrosion
Car2on /teel

4ocali0ed Corrosion
Car2on /teel

4ocali0ed Corrosion
M(OH), OH) CI)
Volts: SaturedCl omelHaf-C RefrncElt rode Car!onStel(<#E5y0)=iA+-21R.3:H9>"'h&ud67 (an'esAlumi4cCd-5.r;08 nesium 9#CAli-a <5>aloy+2*.0S@Resit9rn3C!1A%"&6um8#E)c$v-:? 2*."30+@51) -./0+V =itanumSles01Aoy59#C<EvrGc(& $el2."35ys)+E<>ao@6C:8#0HAG .5R"B CrumandGlv car!ey"CosinfS- centradHyo#i$l%sAC nferc&odi's-hlAat AS()*+5,2C10r -./01 ./2 -./)21 ./0 -./523+* -)/.210 /5 -)/23+

M(OH), OH) M,*

+)

#tationar( 3lectrodes "ll of the dissolution occurs in one location )ei*ht loss measurement not useful %ocal Penetration
#ometimes local ,ea&enin* Ma( or ma( not =eopardi.e structural inte*rit( -etermines >failure?

Source: Corrosion, ASM Handbook, Volume 1 , 1!"#

)otential and Current Fields in Electrolyte in the Picinity of a 4ocali0ed Corrosion /ite
)otential

V olts:Sa turaed Calome lHaf-C elRf renc Electrod CadmiAlu umin4c(a'es (a'nesium (<CA Aloy2-)"C:erHi'h&ut95a#E0!nS no2-);0567eraliumd 8 %*.-)#ic$elra9C<5Aoy=n Silver)3-0:H1RE2.+on?AysC#c$>a" el5.#i- .Cr Aloy2Cast9rn#i-ReS3.1 2Co:er-#ic$l50S@.st1!6n8 "1)25 1)3 Aloy3.6#ic$e2(<E5G@9C>*0 Ceso:8aly0."6HA%&9i+253 .0"5RBum82)* 5.32"0+@ 5. =ita niumStalesA9#C< Aloy2@SiverG9#C<5>a01.Es)3 "2)+E5y. -./0 -./0+V&latin um *21 05r) CrumG andScr!lvi ery"CosiS- onceCf#i$ traedHl%sAoy ydrochlsCnfe e&rocdinA 's-AS(at25C )*+5,

+ Current (ensity

-./0 -./12 ) .-/)2 -./10 /5 -./23 /+ -./*) )/ -)/21 -)/052 -)/3+

#nodic

Lo"ali+ed Anodi" ,ite

Cathodic

Metal