Dislocation-Based CPFEM and Phase-Field Study on the Stress Corrosion Cracking of Randomly Textured Magnesium Alloys

Magnesium (Mg) alloys are promising for automotive lightweighting and the low-altitude economy, yet their reliability is challenged by stress corrosion cracking (SCC). To realize a quantitative and physics-based evaluation of SCC resistance, this study develops a mesoscale simulation framework coupling dislocation density-based crystal plasticity with an anodic dissolution phase-field model. A 2D representative volume element is constructed for randomly textured polycrystalline Mg to investigate the synergistic acceleration of corrosion by dislocation slip and hydrostatic stress. Results show that heterogeneous dislocation multiplication induced by pre-deformation is the decisive factor in corrosion path selection. In soft-oriented grains, high dislocation densities elevate the interface kinetic coefficient to levels substantially higher than those in hard-oriented regions. Notably, within such soft grains, the contribution of dislocation density to the interface kinetic coefficient can be up to 7.7 times that of hydrostatic stress, establishing dislocation-induced lattice disorder as the primary accelerator for transgranular corrosion. Hard-oriented grains effectively impede corrosion propagation due to restricted dislocation proliferation. This study elucidates how grain orientation-dependent dislocation evolution regulates corrosion morphology, revealing that the random texture delays overall structural failure based on a "weakest-link" mechanism.