Computer modeling and fatigue tests of changes in the crack propagation rate encountered by pitting corrosion

RIP2025-00020: This study investigates the effects of pitting corrosion on crack propagation rates in aluminum aerospace structures, integrating fatigue testing with advanced computer modeling to assess fatigue durability under cyclic loading. Aluminum alloys, commonly used in aircraft, are particularly susceptible to localized pitting corrosion, which can initiate microcracks and significantly influence crack growth rates, especially in the corrosive environments encountered in service. Rigorous fatigue tests were conducted to quantify crack growth in corroded specimens, revealing that pits substantially accelerate crack propagation by intensifying local stress concentrations. Computational models, calibrated with experimental fatigue data, simulate the impact of pit morphology, depth, and distribution on crack growth behavior, providing a comprehensive view of crack evolution influenced by corrosion. The results underscore a nonlinear relationship between pit-induced stress and fatigue life reduction, enabling more accurate predictions of service life for aluminum aerospace structures. These insights are critical for optimizing design strategies, enhancing corrosion resistance, and ensuring long-term structural integrity in aviation applications.