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<p>This study evaluates the fatigue performance of ASTM A242 Corten steel and its Cold Metal Transfer (CMT) welded joints using ER70S-6 filler wire. The presence and distribution of alloying elements like Mn, Si, and Cu in the weld region are confirmed by elemental analysis (EDS). The presence of Fe<sub>3</sub>O<sub>4</sub> and Fe<sub>2</sub>O<sub>3</sub> (iron oxide phases) was detected in the welded region by x-ray diffraction (XRD), which could serve as potential crack initiation sites under cyclic loading. Fatigue failure mechanisms were found to change from ductile striation-dominated crack propagation at lower-stress levels (141.9&#xa0;MPa) to mixed-mode fracture with cleavage features and secondary cracking at higher-stress levels (236.5&#xa0;MPa) based on fractographic analysis. The specimen survived 1 × 10<sup>6</sup> cycles without failure at the lowest applied alternating stress of 118.3&#xa0;MPa, representing the run-out condition. Weibull distribution analysis of the welded samples showed shape parameter (<i>β</i>) values ranging from 1.7 to 2.3, indicating moderate fatigue life scatter and progressive fatigue damage accumulation under cyclic loading. The fatigue life behavior was further modeled using the Basquin equation, demonstrating that reduced stress amplitudes significantly improve fatigue life. The obtained results emphasize the importance of controlling weld microstructure to achieve high fatigue resistance and provide insights for the development of durable welded structures subjected to cyclic loading.</p>

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Experimental Investigation of Fatigue Behavior of ASTM A242 Corten Steel Using Cold Metal Transfer Welding

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Sreejith S. Nair,
  • I. Rajendran

摘要

This study evaluates the fatigue performance of ASTM A242 Corten steel and its Cold Metal Transfer (CMT) welded joints using ER70S-6 filler wire. The presence and distribution of alloying elements like Mn, Si, and Cu in the weld region are confirmed by elemental analysis (EDS). The presence of Fe3O4 and Fe2O3 (iron oxide phases) was detected in the welded region by x-ray diffraction (XRD), which could serve as potential crack initiation sites under cyclic loading. Fatigue failure mechanisms were found to change from ductile striation-dominated crack propagation at lower-stress levels (141.9 MPa) to mixed-mode fracture with cleavage features and secondary cracking at higher-stress levels (236.5 MPa) based on fractographic analysis. The specimen survived 1 × 106 cycles without failure at the lowest applied alternating stress of 118.3 MPa, representing the run-out condition. Weibull distribution analysis of the welded samples showed shape parameter (β) values ranging from 1.7 to 2.3, indicating moderate fatigue life scatter and progressive fatigue damage accumulation under cyclic loading. The fatigue life behavior was further modeled using the Basquin equation, demonstrating that reduced stress amplitudes significantly improve fatigue life. The obtained results emphasize the importance of controlling weld microstructure to achieve high fatigue resistance and provide insights for the development of durable welded structures subjected to cyclic loading.