The main cable is the primary load-bearing component of a long-span multi-tower suspension bridge. The interaction between a dead load, vehicle load, wind load, and the corrosion environment leads the main cable wire to exhibit tribo-corrosion-fatigue behaviors. This behavior causes wire wear and deterioration, as well as a reduction in the effective cross-sectional area. This leads to the gradual deterioration of the wire’s load-bearing strength and seriously affects the load-bearing safety of the main cable. In order to ensure the safety of suspension bridges, it is critical to investigate the gradual deterioration behavior of the main cable wire’s load-bearing strength. A wire tribo-corrosion-fatigue test rig was established to test the wire under different friction pairs (saddle groove or parallel wires). The cross-sectional failure area of the wire with different pairs was obtained by super-depth electron microscopy and calculation. The damage degree evolution model and the deterioration model of the wire load-bearing strength were established by combining the theory of damage mechanics and the finite element method. The results show that, as contact and fatigue loads increase, so does the cross-sectional failure area of the fatigue steel wire. The fatigue wire’s damage degree has a good quadratic function relationship with fatigue cycles. The damage degree of the wire increases and the load-bearing strength decreases with increasing contact load and fatigue load. The load-bearing strength of the wire changes little at the beginning and decreases with increasing fatigue cycles. The results have fundamental significance for the life prediction of the main cable wires of suspension bridges.

The effect of contact load and relative displacement on tribo-corrosion interaction of parallel steel wires of main cable in the suspension bridge was investigated in this study. A self-made tribo-corrosion test bench was employed to conduct tribo-corrosion tests of parallel steel wires in 3.5% (wt%) NaCl solution and deionized water under different contact loads and different relative displacements. The friction coefficient and wear coefficient of wires were presented. Electrochemical corrosion behavior (Tafel polarization curves, Nyquist diagram, and equivalent circuit diagram) was characterized by electrochemical analyzer. Wear morphology was observed by scanning electron microscope. Wear volume loss and corrosion-wear interaction were quantitatively demonstrated by high-precision weighing balance. The results show that the electrochemical corrosion ability of the steel wires increases with the increase of the contact load or relative displacement. The increased contact load or relative displacement increases the volume loss of corrosion-wear and pure wear, but decreases the wear coefficient. The wear mechanisms in 3.5% NaCl solution are adhesive wear, abrasive wear, and corrosive wear as compared to adhesive wear and abrasive wear in deionized water under different contact loads. The wear mechanisms of parallel steel wires are slightly different under different relative displacements. But the main wear mechanisms are similar to that under different contact loads. The interaction effects of corrosion and wear produced by the contact load and relative displacement are all the synergistic effects.