Experimental and Numerical Investigation of Corrosion-Induced Failures in copper-tin alloy (Cu-Sn) and aluminum-magnesium alloy (Al-Mg) connectors: A Stress–Corrosion Coupling Analysis

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Year : 2026 | Volume : 14 | 02 | Page :
    By

    Rajev Kumar Sharma,

  • Ajay Sharma,

  • Sandeep Kanaujia,

  1. Research Scholar, Department of Electronics and Communication Engineering, United University, Prayagraj, Uttar Pradesh, India
  2. Professor, Department of Electronics and Communication Engineering, United University, Prayagraj, Uttar Pradesh, India
  3. Professor, Department of Electronics and Communication Engineering, United College of Engineering & Research, Prayagraj, Uttar Pradesh, India

Abstract

The utilization of an integrated experimental and finite element modelling (FEM) methodology, this study investigates the degradation and failure mechanisms in polymer composite electrical connectors exposed to aggressive environmental conditions. Epoxy- and polyamide-based composites, reinforced with carbon and glass fibers, were subjected to accelerated salt spray and humidity–temperature cycles to simulate prolonged outdoor exposure. Electrochemical and environmental aging experiments revealed that chloride ions and moisture ingress were responsible for matrix microcracking, fiber–matrix interface debonding, and dielectric degradation, all of which contributed to the loss of mechanical integrity and conductivity. The stress–corrosion and hygrothermal coupling effects were efficiently represented through FEM simulations, validated using surface morphology and microstructural analysis. Furthermore, the simulations accurately predicted fracture initiation zones and damage propagation paths within the composite matrix. A strong correlation between experimental and numerical findings confirmed that environmental degradation and mechanical stress act synergistically, accelerating failure progression. These results emphasize the importance of protective surface treatments, barrier coatings, and digital twin integration in polymer composite connectors for railway signalling systems operating under extreme environmental conditions, while also offering a predictive framework for assessing long-term durability and service life.

Keywords: Alloys Synthesis Techniques, Electrochemical, Corrosion-induced failure, copper-tin alloy (Cu-Sn) and aluminium-magnesium alloy (Al-Mg), Stress–corrosion coupling.

How to cite this article:
Rajev Kumar Sharma, Ajay Sharma, Sandeep Kanaujia. Experimental and Numerical Investigation of Corrosion-Induced Failures in copper-tin alloy (Cu-Sn) and aluminum-magnesium alloy (Al-Mg) connectors: A Stress–Corrosion Coupling Analysis. Journal of Polymer & Composites. 2026; 14(02):-.
How to cite this URL:
Rajev Kumar Sharma, Ajay Sharma, Sandeep Kanaujia. Experimental and Numerical Investigation of Corrosion-Induced Failures in copper-tin alloy (Cu-Sn) and aluminum-magnesium alloy (Al-Mg) connectors: A Stress–Corrosion Coupling Analysis. Journal of Polymer & Composites. 2026; 14(02):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=239595


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Ahead of Print Subscription Original Research
Volume 14
02
Received 07/11/2025
Accepted 26/12/2025
Published 02/04/2026
Publication Time 146 Days
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