Abstract
Electroplating of aerospace parts generates hydrogen embrittlement, which is controlled by 200-h sustained-load tests performed on cylindrical notched samples. Those tests are costly and offer only a pass-or-fail assessment, with limited interpretability. In this article, we propose a new fractographic method to obtain a quantitative indication of the embrittlement severity of electroplated samples that failed the sustained-load test. On the fracture surfaces of failed samples, intergranular (IG) zones were observable at fracture initiation sites, surrounded by ductile zones, with intermediate regions containing mixed (ductile+IG) features. Within the framework of the recently proposed Hydrogen-Enhanced Plasticity-Mediated DEcohesion mechanism (HELP-mediated HEDE), we argue that there is a correlation between the intergranular appearance of the fracture surfaces and the subcritical nature of the crack propagation. Using this argument, we computed the stress intensity factor K for each crack and loading condition, with the input of intergranular zone sizes and finite element analysis. Minimum and maximum K values were identified and statistics of the extremes was used to calculate the minimum expected K values for various embrittlement conditions. It is proposed that this value is an estimate of the threshold for embrittlement, Kth. Values of Kth between 9 MPa m0.5 and 30 MPa m0.5 were measured for various plating conditions. Those estimations are more conservative than the thresholds reported in the literature, which were measured using more complex experimental procedures. Moreover, the fracture toughness estimated with the maximum K values was possibly affected by high initial hydrogen concentrations as per the HELP+HEDE embrittlement mechanism.
Published Version
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