Test and simulation of corroded high strength steel wires: From scanned morphology feature to mechanical degradation

This paper presents a coupled experimental-numerical study aimed at understanding the mechanical behavior of corroded high-strength steel wires. Accelerated corrosion tests were conducted on steel wires to achieve varying corrosion levels, and the mechanical properties of the corroded wires were characterized by tensile test. The surface morphology of the corroded wires was derived by 3D optical scanning and point cloud models was generated that precisely captured the surface pits. These models were then converted into solid models by surface reconstruction and finite element discretization. Numerical simulations, based on reconstructed surface morphology, effectively predict key mechanical characteristics and align closely with experimental data. The research establishes relationships between statistical pit parameters and macro-mechanical properties, providing valuable insights for predicting the mechanical performance of corroded wires and evaluating the integrity of structures compromised by corrosion.