Experimental investigation of fracture mechanism in organically modified silica-based coating applied on austenitic stainless steel AISI 904L under monotonic and very high cycle fatigue loading

Surface morphology significantly influences the fatigue life of the metallic materials. Therefore, improving surface performance is important for economic and safety applications. Silica-based coatings are anticipated to protect the metallic materials under synergistic operating conditions, such as fatigue and corrosion. However, pure inorganic silica-based coatings are brittle and fail to protect metallic materials. The properties of the sol–gel coatings can be determined by optimizing synthesis factors, such as synthesis steps, precursors, solvents, and catalysts. Organically modified silica-based sol–gel coatings were synthesized using 3-glycidoxypropyl trimethoxysilane and 3-aminopropyltriethoxysilane as precursors, with ethanol as the solvent. The resulting coating was named EtOH. This coating was applied on the surface of stable austenitic stainless steel AISI 904L with the dip coating method. The fracture behavior of the coating during monotonic loading has been studied by interrupted tensile tests at different load steps and examined closely with scanning electron microscopy. On the other hand, very high cycle fatigue experiments were conducted using an ultrasonic fatigue testing system at load frequency of 20 kHz on coated specimens to investigate the fracture behavior of the coating during cyclic loading. Three different kinds of fracture due to stress relaxation in the coating and at its interface with substrate were observed in monotonic loading. The same kinds of stress relaxation were observed in cyclic loading with the difference being that the range of experienced elongation in cyclic tests was significantly smaller. Therefore, the fracture in cyclic loading were concentrated in the vicinity of macro crack. The application of organically modified coatings could suppress the persistent slip bands and result in increased fatigue life for coated specimens. The research was supported by the National Science Centre, Poland under the OPUS + LAP project ‘Research on the influence of self-healing, organic-inorganic sol-gel layers on the corrosion resistance and fatigue of steel in the VHCF range’ UMO 2020/39/I/ST5/03493, as well as funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) – 465237729.