Mechanical Property Degradation Behavior and Fatigue Life Analysis of Corroded High-Strength Steel Wires

Investigating the effects of corrosion on the mechanical and fatigue properties of steel wires is critical for the safety assessment of bridge cable structures.This study focuses on high-strength galvanized steel wires used for bridge cables, with a diameter of 7 mm and a strength grade of 1770 MPa. Specimens with varying mass loss rates η were prepared by electrochemical corrosion method, and systematic tensile and fatigue tests were conducted to study the effects of corrosion on the fundamental mechanical properties and fatigue life of the steel wires. The results indicate that the elastic modulus of the steel wires decreases slightly with the increase of η but still meets the requirements of relevant standards. In contrast, the yield strength and tensile strength degrade significantly, while ductility is particularly susceptible to corrosion, showing more severe deterioration. When η is less than 2.75%, the corroded steel wires still maintain favorable fatigue resistance at a nominal stress amplitude of 360 MPa. Once η exceeds this threshold, their fatigue life decreases significantly in a nonlinear manner with increasing η. The fatigue life predicted by a finite element model (FEM) reconstructed based on the 3D scanning geometry of corroded steel wires and combined with the Abaqus/fe-safe module shows good agreement with the experimental results, indicating that this approach can provide a valuable reference for the durability assessment of bridge cables.