Influence of residual stress and its relaxation on the corrosion bending fatigue resistance of EA4T axle steel treated by ultrasonic surface rolling.

• The surface properties of EA4T axle steel treated by ultrasonic surface rolling process (USRP) are investigated. • Effect of USRP on the electrochemical corrosion resistance and corrosion fatigue performance is elucidated. • Residual stress relaxation mechanism of USRP-treated EA4T axle steel in air and corrosion is revealed. • Influence of residual stress relaxation on the corrosion fatigue resistance is clarified. The fatigue properties and residual stress relaxation behavior of EA4T axle steel treated by ultrasonic surface rolling process (USRP) are investigated in air and corrosive environments. The result reveals that the surface roughness (Ra) is decreased from 1.42 to 0.17 μm after the USRP. A surface layer with ultrafine grains, work hardening, and compressive residual stress (CRS) is achieved by the USRP. Compared with the as-machined specimens, the USRP specimens exhibit slightly lower electrochemical corrosion resistance but superior fatigue performance in air and corrosive environments. The dislocation density is significantly decreased in the corrosive environment during fatigue loads, accompanied by a rapid relaxation of surface CRS. The influence of USRP on the corrosion fatigue performance is elucidated. The residual stress relaxation mechanism and its influence on fatigue resistance are also analyzed. [ABSTRACT FROM AUTHOR]