Mechanistic Insights into LME Crack-Induced High-Cycle Fatigue Degradation in Zn-Coated High-Strength Boron Steel

Liquid metal embrittlement (LME) during hot stamping of Zn-coated high-strength steels poses significant challenges to the long-term durability of automotive components. This study investigates how ~30 μm deep LME cracks affect the mechanical behavior of Zn-coated high-strength boron steel. LME-free flat specimens were compared with hat-shaped specimens containing LME cracks. While tensile strength and ductility exhibited minimal changes, the high-cycle fatigue limit (R = −1, 107 cycles) decreased by 10.9% from 550 MPa to 490 MPa in hat-shaped specimens. Fractographic examination revealed distinct stress-dependent crack initiation mechanisms: at high stress amplitudes (≥690 MPa), LME cracks competed with intrinsic substrate defects but did not dominate fatigue failure. In contrast, at moderate-to-low stress amplitudes (≤630 MPa), LME cracks dominated fatigue degradation through a multi-site crack initiation tendency. El Haddad analysis positioned these cracks at the short-to-long crack transition boundary (l ≈ l0). Preliminary fracture mechanics analysis reveals that conventional single-crack LEFM models systematically overestimate the fatigue threshold stress for LME-affected specimens, a discrepancy qualitatively attributed to the high surface density and morphological complexity of LME crack networks and to chemically assisted grain boundary weakening induced by liquid Zn infiltration—effects not captured by standard fracture mechanics frameworks. These results establish the stress-dependent mechanisms governing LME crack-induced fatigue degradation and provide a mechanistic basis for the development of more accurate fatigue life prediction methods for Zn-coated hot-stamped high-strength steels.