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Article

Fatigue Damage of Aluminum Alloy Overhead Line Conductors Initiated by Fretting

1
Faculty of Non-Ferrous Metals, AGH University of Krakow, al. Mickiewicza 30, 30-059 Krakow, Poland
2
Łukasiewicz Research Network—Institute of Non-Ferrous Metals, 32-050 Skawina, Poland
*
Author to whom correspondence should be addressed.
Materials 2025, 18(17), 4103; https://doi.org/10.3390/ma18174103
Submission received: 13 August 2025 / Revised: 29 August 2025 / Accepted: 30 August 2025 / Published: 1 September 2025
(This article belongs to the Special Issue Microstructural and Mechanical Properties of Metal Alloys)

Abstract

Fatigue failure of overhead line conductors made of AlMgSi alloys is much more complex than fatigue failure of a single wire. The main difference lies in the fretting phenomenon, which is a significant mechanism initiating fatigue damage. It is generated because of micro-movements between individual wires or outer wires and overhead line fittings. Such movements are mainly caused by aeolian vibrations, which lead to degradation of wire surface, initiation of microcracks, and premature failure of multiple wires. Research based on laboratory experiments and modeling studies simulating real operating conditions made it possible not only to identify the mechanisms leading to failure but also to assess the impact of working conditions on their evolution. According to the obtained results, properly selected heat treatment parameters influence both the mass decrease of the wires and number of cycles to failure due to fretting fatigue. Further development of materials, protective coatings, and methods of durability prediction will reduce the impact of fretting on fatigue failure and thus increase the reliability of power lines.
Keywords: fatigue failure; fatigue damage; fretting; overhead line conductors; aluminum alloys; non-ferrous metals fatigue failure; fatigue damage; fretting; overhead line conductors; aluminum alloys; non-ferrous metals

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MDPI and ACS Style

Nowak, A.; Strzępek, P.; Korczak, P. Fatigue Damage of Aluminum Alloy Overhead Line Conductors Initiated by Fretting. Materials 2025, 18, 4103. https://doi.org/10.3390/ma18174103

AMA Style

Nowak A, Strzępek P, Korczak P. Fatigue Damage of Aluminum Alloy Overhead Line Conductors Initiated by Fretting. Materials. 2025; 18(17):4103. https://doi.org/10.3390/ma18174103

Chicago/Turabian Style

Nowak, Andrzej, Paweł Strzępek, and Piotr Korczak. 2025. "Fatigue Damage of Aluminum Alloy Overhead Line Conductors Initiated by Fretting" Materials 18, no. 17: 4103. https://doi.org/10.3390/ma18174103

APA Style

Nowak, A., Strzępek, P., & Korczak, P. (2025). Fatigue Damage of Aluminum Alloy Overhead Line Conductors Initiated by Fretting. Materials, 18(17), 4103. https://doi.org/10.3390/ma18174103

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