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Materials 2016, 9(3), 141; doi:10.3390/ma9030141

Surface Characterizations of Fretting Fatigue Damage in Aluminum Alloy 7075-T6 Clamped Joints: The Beneficial Role of Ni–P Coatings

1
Discipline of Mechanical Engineering, School of Computer Science, Engineering and Mathematics, Flinders University, Clovelly Park SA 5042, Australia
2
Department of Mechanical & Aerospace Engineering, Monash University, Clayton VIC 3800, Australia
3
Department of Materials Science and Engineering, Monash University, Clayton VIC 3800, Australia
*
Author to whom correspondence should be addressed.
Academic Editor: Nicola Pugno
Received: 14 November 2015 / Revised: 9 February 2016 / Accepted: 23 February 2016 / Published: 27 February 2016
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Abstract

This paper aims to characterize the surface damage as a consequence of fretting fatigue in aluminum alloy 7075-T6 plates in double-lap bolted joints through XRD, surface profilometry, and SEM analyses. The main focus was on the surface roughness and chemical phase composition of the damaged zone along with the identification of fretting fatigue crack initiations over the surface of the material. The surface roughness of the fretted zone was found to increase when the joint was clamped with a higher tightening torque and tested under the same cyclic loading. Additionally, MgZn2 (η/ή) precipitates and ZnO phase were found to form onto the surface of uncoated aluminum plate in the fretted and worn zones. The formation of the ZnO phase was understood to be a result of frictional heat induced between the surface of contacting uncoated Al 7075-T6 plates during cyclic loading and exposure to the air. The beneficial role of electroless nickel-phosphorous (Ni–P) coatings in minimizing the fretting damage and thus improving the fretting fatigue life of the aluminum plates was also studied. The results showed that the surface roughness decreased by approximately 40% after applying Ni–P coatings to the Al 7075-T6 plates. View Full-Text
Keywords: fretting fatigue; aluminum alloys; Ni–P coatings; surface roughness; clamped joints fretting fatigue; aluminum alloys; Ni–P coatings; surface roughness; clamped joints
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Oskouei, R.H.; Barati, M.R.; Ibrahim, R.N. Surface Characterizations of Fretting Fatigue Damage in Aluminum Alloy 7075-T6 Clamped Joints: The Beneficial Role of Ni–P Coatings. Materials 2016, 9, 141.

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