Field application of a nanometallic multilayer coating for fatigue life extension of steel bridge welds

Fatigue failure of welded joints is one of the most critical degradation mechanisms in steel bridges, limiting their service life and compromising structural safety. Post‐weld treatment using a nanometallic multilayer (NMM) consisting of alternating nickel and copper layers has shown significant potential to mitigate fatigue‐induced damage. The NMM, deposited via electroplating, enhances the fatigue resistance of welded joints by reducing surface roughness, introducing beneficial residual stresses, and shielding the weld from environmental influences. Laboratory‐scale experiments have demonstrated up to a sixfold extension of service life for butt‐welded specimens under cyclic loading. Building on these findings, this study presents the first successful application of the NMM technology on an existing bridge structure sample. A portable coating device was developed and refined to enable on‐site application under practical conditions, including overhead deposition ‐ a critical requirement for NMM‐treatment of real bridges. The device establishes a liquid‐tight seal against the steel surface, circulates electrolyte via a peristaltic pump, and incorporates a nickel anode to ensure controlled deposition. By applying an external current, copper and nickel ions are deposited onto the weld seam, forming the NMM coating directly in situ. The results confirm the adaptability of the device to real bridge structures, demonstrating its potential for integration into maintenance strategies of aging infrastructure. This marks a crucial step towards large‐scale implementation of nanometallic multilayer technology for extending the service life and sustainability of steel bridges.

Content

Subjects

Steel bridges

Welded joints

Fatigue life extension

Nanometallic multilayer (NMM)

Electroplating

Post-weld treatment

DDC Class

624: Civil Engineering, Environmental Engineering

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https://creativecommons.org/licenses/by/4.0/

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publishedVersion

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ce papers - 2026 - Hausig - Field Application of a Nanometallic Multilayer Coating for Fatigue Life Extension of Steel.pdf

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Main Article

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