Study on stress corrosion behavior and failure mechanism of galvanized bolts in complex coal mine environments
The premature failure of bolts caused by stress corrosion cracking (SCC) is a common issue in the global mining industry. Studies have shown that hot-dip galvanizing is an effective solution, but the first widespread application of galvanized bolts in Xin’Shang’Hai No. 1 coal mine, China, experience...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-01-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785424029764 |
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| author | Zhe He Nong Zhang Zhengzheng Xie Chao Ma Changliang Han Fan Zhang Huiqing Wang Saad S. Alarifi |
| author_facet | Zhe He Nong Zhang Zhengzheng Xie Chao Ma Changliang Han Fan Zhang Huiqing Wang Saad S. Alarifi |
| author_sort | Zhe He |
| collection | DOAJ |
| description | The premature failure of bolts caused by stress corrosion cracking (SCC) is a common issue in the global mining industry. Studies have shown that hot-dip galvanizing is an effective solution, but the first widespread application of galvanized bolts in Xin’Shang’Hai No. 1 coal mine, China, experienced extensive failures. To thoroughly investigate the fracture failure mechanism, this paper employed a comprehensive approach that included macro mechanical property testing, corrosion experiments, and micro-scale characterization. The findings indicate that significant stress concentration occurred on the surface threads of the bolts under high mine pressure, serving as the primary inducer of SCC in the bolts. Under long-term stress corrosion conditions, the peak strength of high-strength coated bolts, hot-dip galvanized bolts, and ordinary bolts decreased by 3.73%, 20.54%, and 11.60% respectively. Among them, the coated bolts largely maintained their original mechanical properties and had the best anti-corrosion capability. The performance of galvanized bolts deteriorated more than ordinary ones, indicating that they could not suppress the SCC of the bolts and even exacerbated the SCC of the bolt body after the galvanized layer cracked. Hydrogen content analysis showed that after service in the mine, the hydrogen content in the body of the galvanized bolts increased by 304.48%, significantly raising the risk of hydrogen induced cracking (HIC). Additionally, HIC-sensitive structures (tempered martensite) and typical features of HIC (white spots) were found in the galvanized bolts, providing strong evidence of HIC occurrence during their service in the mine. In short, the instantaneous fracture of galvanized bolts was mainly caused by the interaction of stress concentration cracking due to the geometry of the bolts and HIC under stress corrosion failure. Thus, in deep underground engineering, it is not recommended to promote the use of galvanized anti-corrosion processes and Class A shaped bolts, especially in environments with high stress and high mineralization. Instead, high-strength coated bolts are advised to replace galvanized ones to enhance the reliability and safety of bolt support. |
| format | Article |
| id | doaj-art-3af855ca65ea4c799f893f9a9742b08d |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-3af855ca65ea4c799f893f9a9742b08d2025-01-19T06:25:43ZengElsevierJournal of Materials Research and Technology2238-78542025-01-013417591776Study on stress corrosion behavior and failure mechanism of galvanized bolts in complex coal mine environmentsZhe He0Nong Zhang1Zhengzheng Xie2Chao Ma3Changliang Han4Fan Zhang5Huiqing Wang6Saad S. Alarifi7School of Mines, State Key Laboratory of Coal Exploration and Intelligent Mining, China University of Mining and Technology, Xuzhou, 221116, ChinaSchool of Mines, State Key Laboratory of Coal Exploration and Intelligent Mining, China University of Mining and Technology, Xuzhou, 221116, China; School of Civil Engineering, Xuzhou University of Technology, Xuzhou, 221116, China; Corresponding author. School of Mines, State Key Laboratory of Coal Exploration and Intelligent Mining, China University of Mining and Technology, Xuzhou, 221116, China.School of Mines, State Key Laboratory of Coal Exploration and Intelligent Mining, China University of Mining and Technology, Xuzhou, 221116, ChinaSchool of Civil Engineering, Xuzhou University of Technology, Xuzhou, 221116, ChinaSchool of Mines, State Key Laboratory of Coal Exploration and Intelligent Mining, China University of Mining and Technology, Xuzhou, 221116, ChinaSchool of Materials Science and Physics, China University of Mining and Technology, Xuzhou, 221116, ChinaShandong Yanxin Mining Materials Processing Co.,LTD, Shandong Energy Group, Xintai, 271200, ChinaDepartment of Geology and Geophysics, College of Science, King Saud University, Riyadh, 11451, Saudi ArabiaThe premature failure of bolts caused by stress corrosion cracking (SCC) is a common issue in the global mining industry. Studies have shown that hot-dip galvanizing is an effective solution, but the first widespread application of galvanized bolts in Xin’Shang’Hai No. 1 coal mine, China, experienced extensive failures. To thoroughly investigate the fracture failure mechanism, this paper employed a comprehensive approach that included macro mechanical property testing, corrosion experiments, and micro-scale characterization. The findings indicate that significant stress concentration occurred on the surface threads of the bolts under high mine pressure, serving as the primary inducer of SCC in the bolts. Under long-term stress corrosion conditions, the peak strength of high-strength coated bolts, hot-dip galvanized bolts, and ordinary bolts decreased by 3.73%, 20.54%, and 11.60% respectively. Among them, the coated bolts largely maintained their original mechanical properties and had the best anti-corrosion capability. The performance of galvanized bolts deteriorated more than ordinary ones, indicating that they could not suppress the SCC of the bolts and even exacerbated the SCC of the bolt body after the galvanized layer cracked. Hydrogen content analysis showed that after service in the mine, the hydrogen content in the body of the galvanized bolts increased by 304.48%, significantly raising the risk of hydrogen induced cracking (HIC). Additionally, HIC-sensitive structures (tempered martensite) and typical features of HIC (white spots) were found in the galvanized bolts, providing strong evidence of HIC occurrence during their service in the mine. In short, the instantaneous fracture of galvanized bolts was mainly caused by the interaction of stress concentration cracking due to the geometry of the bolts and HIC under stress corrosion failure. Thus, in deep underground engineering, it is not recommended to promote the use of galvanized anti-corrosion processes and Class A shaped bolts, especially in environments with high stress and high mineralization. Instead, high-strength coated bolts are advised to replace galvanized ones to enhance the reliability and safety of bolt support.http://www.sciencedirect.com/science/article/pii/S2238785424029764SCCHICMicro-scale characterizationFailure mechanismGalvanized boltsHigh mineralization mine water |
| spellingShingle | Zhe He Nong Zhang Zhengzheng Xie Chao Ma Changliang Han Fan Zhang Huiqing Wang Saad S. Alarifi Study on stress corrosion behavior and failure mechanism of galvanized bolts in complex coal mine environments Journal of Materials Research and Technology SCC HIC Micro-scale characterization Failure mechanism Galvanized bolts High mineralization mine water |
| title | Study on stress corrosion behavior and failure mechanism of galvanized bolts in complex coal mine environments |
| title_full | Study on stress corrosion behavior and failure mechanism of galvanized bolts in complex coal mine environments |
| title_fullStr | Study on stress corrosion behavior and failure mechanism of galvanized bolts in complex coal mine environments |
| title_full_unstemmed | Study on stress corrosion behavior and failure mechanism of galvanized bolts in complex coal mine environments |
| title_short | Study on stress corrosion behavior and failure mechanism of galvanized bolts in complex coal mine environments |
| title_sort | study on stress corrosion behavior and failure mechanism of galvanized bolts in complex coal mine environments |
| topic | SCC HIC Micro-scale characterization Failure mechanism Galvanized bolts High mineralization mine water |
| url | http://www.sciencedirect.com/science/article/pii/S2238785424029764 |
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