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<p>This study investigates the pitting evolution and corrosion fatigue mechanism of 2200&#xa0;MPa-grade Zn–Al coated steel wires. The results show that corrosion progresses from coating depletion to substrate pitting through an autocatalytic cycle involving anodic dissolution and hydrolytic acidification. Pit propagation through lateral coalescence and longitudinal development contributes to stress concentration and early crack initiation. Consequently, these early-stage pits trigger a sharp reduction in fatigue life by shifting the failure mode from matrix-defect-dominated fracture to surface-pit-dominated cracking. Notably, the coupled failure is associated with combined mechanical loading and corrosion interaction, wherein cyclic loading mechanically facilitates the transport of corrosive ions to the crack tip, sustaining active dissolution. These findings provide practical insight for the durability evaluation of ultra-high-strength cables.</p>

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Failure Analysis of 2200 MPa Zn–Al Coated Bridge Wire Under Salt Spray and Corrosion-Fatigue Loading

  • 期刊论文

  • 发表日期：

    2026年6月20日

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  • Hongbo Wang,
  • Rumeng Wang,
  • Kedao Chen,
  • Shuai Li,
  • Jingquan Wang,
  • Jun Zhao,
  • Jian Chen

摘要

This study investigates the pitting evolution and corrosion fatigue mechanism of 2200 MPa-grade Zn–Al coated steel wires. The results show that corrosion progresses from coating depletion to substrate pitting through an autocatalytic cycle involving anodic dissolution and hydrolytic acidification. Pit propagation through lateral coalescence and longitudinal development contributes to stress concentration and early crack initiation. Consequently, these early-stage pits trigger a sharp reduction in fatigue life by shifting the failure mode from matrix-defect-dominated fracture to surface-pit-dominated cracking. Notably, the coupled failure is associated with combined mechanical loading and corrosion interaction, wherein cyclic loading mechanically facilitates the transport of corrosive ions to the crack tip, sustaining active dissolution. These findings provide practical insight for the durability evaluation of ultra-high-strength cables.