Corrosion and Embrittlement in High-Strength Wires of Suspension Bridge Cables

An in-depth analysis of the deterioration mechanisms in high-strength wires of suspension bridge cables is presented. Accelerated cyclic corrosion tests were conducted to assess the relative effect of corrosion on galvanized and ungalvanized wires. Samples were corroded under various levels of sustained loads in a cabinet that cyclically applied an acidic salt spray, dry conditions, and 100% relative humidity at elevated temperature, and mass loss, hydrogen concentration, ultimate load, and elongation at failure were measured. Elongation measurements indicated a significant embrittlement of the wires that could not be explained solely by the presence of absorbed hydrogen (hydrogen embrittlement). The main cause of reduction of wire elongation was found to be the surface irregularities induced by the corrosion process. The experimental results were validated through a numerical analysis using a finite-element method model of the corroded steel wire and through a series of scanning electron microscope analyses of the fracture surfaces.