Investigation of small fatigue crack initiation and growth behaviour of nickel base superalloy GH4169

Surface replication method was utilized to monitor the small fatigue crack initiation and growth process of single‐edge‐notch tension specimens fabricated by nickel base superalloy GH4169. Three different stress levels were selected. Results showed that small fatigue cracks of nickel base superalloy GH4169 initiated from grain boundaries or surface inclusions. The small fatigue crack initiation and growth stages took up about 80–90% of the total fatigue life. Multiple major cracks were observed in the notch root, and specimen with more major cracks seemed to have smaller fatigue life under the same test conditions. At the early growth stage, small crack behaviour might be strongly influenced by microstructures; thus, the crack growth rates had high fluctuations. However, the stress level effect on the small fatigue crack growth rates was not distinguishable for the three different stress levels. And no clear differences were found among the crack initiation lives by using replication technique.     

Influence of grain size on the small fatigue crack initiation and propagation behaviors of a nickel-based superalloy at 650 °C

GH4169 at 650 °C in atmosphere was investigated by using single edge notch tensile specimens. The number of main cracks and crack initiation mechanisms at the notch surface strongly depended on the grain size. The crack initiation life accounted for more percentages of the total fatigue life for the alloy with smaller grain size. The fatigue life generally increased with increasing crack initiation life. The small crack transited to long crack when its length reached ˜10 times the grain size.     

Manifestations of dynamic strain aging under low and high cycle fatigue in a type 316LN stainless steel

Influence of Dynamic strain aging (DSA) under low cycle fatigue (LCF) and high cycle fatigue (HCF) loading was investigated by conducting LCF and HCF tests on specimens over a wide range of temperature from 573 to 973 K. DSA was found to be highly pronounced in the temperature range of 823–873 K. DSA was seen to have contrasting implications under LCF and HCF deformation. The cyclic hardening owing to DSA caused an increase in the cyclic stress response under LCF, leading to decrease in cyclic life. On the other hand, the DSA-induced strengthening suppressed the crack initiation phase under HCF where the applied stress remains fixed, leading to an increase in the cyclic life.     

Microstructure-based fatigue modeling of cast A356-T6 alloy

High cycle fatigue (HCF) life in cast Al-Mg-Si alloys is particularly sensitive to the combination of microstructural inclusions and stress concentrations. Inclusions can range from large-scale shrinkage porosity with a tortuous surface profile to entrapped oxides introduced during the pour. When shrinkage porosity is controlled, the relevant microstructural initiation sites are often the larger Si particles within eutectic regions. In this paper, a HCF model is introduced which recognizes multiple inclusion severity scales for crack formation. The model addresses the role of constrained microplasticity around debonded particles or shrinkage pores in forming and growing microstructurally small fatigue cracks and is based on the cyclic crack tip displacement rather than linear elastic fracture mechanics stress intensity factor. Conditions for transitioning to long crack fatigue crack growth behavior are introduced. The model is applied to a cast A356-T6 Al alloy over a range of inclusion severities.     

On the life-controlling microstructural fatigue mechanisms in ductile metals and alloys in the gigacycle regime

The high-cycle fatigue (HCF) behaviour of ductile metals and alloys, and the life-controlling microstructural fatigue mechanisms known from HCF are reviewed critically with respect to their possible role in the gigacycle or ultra-high-cycle fatigue (UHCF) regime. Arguments are presented to support the hypothesis that, at the very low amplitudes of the UHCF regime, fatigue crack initiation, resulting from cyclic strain localization, and slow early Stage I fatigue crack propagation are the life-controlling mechanisms and that these processes can essentially be described in terms of the microstructurally irreversible portion of the cumulative cyclic plastic strain. Emphasis is placed on the important role of the so-called slip irreversibility which decreases as the amplitude becomes lower and lower. Finally, the Manson–Coffin law is reformulated for very low amplitudes in terms of microstructurally relevant parameters, and a fatigue life diagram is developed, based on these preceding microstructural considerations. Important features of this diagram are: (i) the plastic strain fatigue limit in the HCF regime which is related to the threshold for cyclic strain localization in persistent slip bands; and (ii) the transition from this plastic strain fatigue limit to a threshold of negligible slip irreversibility at still lower amplitudes in the UHCF regime.     

再结晶对DD6单晶高温合金轴向高周疲劳性能的影响

为了研究再结晶对二代单晶高温合金DD6高周疲劳性能的影响,对标准热处理的DD6合金进行表面吹砂处理,然后分别在1120℃和1315℃保温4h,以获得不同类型的再结晶组织。在疲劳试验机上分别测试了光滑和含再结晶的DD6合金试样在1070℃的轴向高周疲劳寿命。采用SEM观察DD6合金再结晶组织及疲劳断口。结果表明:胞状再结晶和等轴再结晶降低了DD6合金的轴向高周疲劳性能,胞状再结晶作用小于等轴再结晶;含再结晶的DD6合金试样的轴向高周疲劳断裂机制为类解理断裂和枝晶间的局部韧窝断裂共存的混合断裂;再结晶使DD6合金试样变为多源疲劳断裂。高温条件下,再结晶晶界的存在加快合金试样的氧化损伤,显著缩短早期疲劳裂纹的萌生和扩展时间,降低合金的轴向高周疲劳性能。     

GH4169合金焊接接头高温疲劳裂纹扩展性能试验研究

对GH4169合金焊接接头在650℃下的疲劳裂纹扩展性能进行了测试和分析.结果表明,疲劳裂纹扩展速率、初始裂纹尺寸、裂纹容限和温度对焊接接头的疲劳裂纹扩展寿命都有影响.母材及焊缝的疲劳裂纹扩展速率和裂纹容限均有较大的差异.     

Prediction of fatigue lifetime under multiaxial cyclic loading using finite element analysis

Life prediction for GH4169 superalloy thin tubular and notched specimens were investigated under proportional and nonproportional loading with elastic–plastic finite element analysis (FEA). A strain-controlled tension–torsion loading was carried out by applying the axial and circular displacements on one end of the specimen in the cylindrical coordinate system. Uniaxial cyclic stress–strain data at high temperature were used to describe the multi-linear kinematic hardening of the material. The comparison between FEA and experimental results for thin tubular specimen showed that the built model of FE is reliable. A fatigue damage parameter was proposed to predict the fatigue crack initiation life for notched specimen. The results showed that a good agreement was achieved with experimental data.     

Multiaxial small fatigue crack growth in metals

Observations related to the formation and growth of small cracks ranging from subgrain dimension up to the order of 1 mm are summarized for amplitudes ranging from low cycle fatigue (LCF) to high cycle fatigue (HCF) conditions for polycrystalline metals. Further efforts to improve the accuracy of life estimation which address LCF, HCF and LCF–HCF interactions must consider various factors that are not presently addressed by conventional elastic–plastic fracture mechanics (EPFM) or linear elastic fracture mechanics (LEFM) approaches based on long, self-similar cracks in homogeneous, isotropic materials, nor by conventional HCF design tools such as the ε–N curve, the S–N curve, modified Goodman diagram and fatigue limit.Development of microstructure-sensitive fatigue crack propagation relations relies on deeper understanding of small crack behavior, including (a) interactions with microstructure and lack of constraint for microstructurally small cracks, (b) heterogeneity and anisotropy of cyclic slip processes associated with the orientation distribution of grains, and (c) local mode mixity effects on small crack growth. The basic technology is not yet sufficiently advanced in these areas to implement robust damage tolerant design for HCF. This paper introduces an engineering model which approximates the results of slip transfer calculations related to crack blockage by microstructure barriers; the model is consistent with critical plane concepts for Stage I growth of small cracks, standard cyclic stress–strain and strain–life equations above threshold, and the Kitagawa diagram for HCF threshold behaviors. It is able to correlate the most relevant trends of small crack growth behavior, including crack arrest at the fatigue limit, load sequence effects, and stress state effects.     

Low‐cycle fatigue/high‐cycle fatigue interactions in notched Ti‐6Al‐4V*

Combined low‐cycle fatigue/high‐cycle fatigue (LCF/HCF) loadings were investigated for smooth and circumferentially V‐notched cylindrical Ti–6Al–4V fatigue specimens. Smooth specimens were first cycled under LCF loading conditions for a fraction of the previously established fatigue life. The HCF 10⁷ cycle fatigue limit stress after LCF cycling was established using a step loading technique. Specimens with two notch sizes, both having elastic stress concentration factors of K_t = 2.7, were cycled under LCF loading conditions at a nominal stress ratio of R = 0.1. The subsequent 10⁶ cycle HCF fatigue limit stress at both R = 0.1 and 0.8 was determined. The combined loading LCF/HCF fatigue limit stresses for all specimens were compared to the baseline HCF fatigue limit stresses. After LCF cycling and prior to HCF cycling, the notched specimens were heat tinted, and final fracture surfaces examined for cracks formed during the initial LCF loading. Fatigue test results indicate that the LCF loading, applied for 75% of total LCF life for the smooth specimens and 25% for the notched specimens, resulted in only small reductions in the subsequent HCF fatigue limit stress. Under certain loading conditions, plasticity‐induced stress redistribution at the notch root during LCF cycling appears responsible for an observed increase in HCF fatigue limit stress, in terms of net section stress.     

Ti60钛合金中富钕稀土相颗粒对叶片室温振动疲劳性能的影响

采用振动疲劳实验及SEM断口分析等方法,研究了含稀土元素Nd的Ti60高温钛合金稀土相颗粒对叶片振动疲劳裂纹萌生的影响.结果表明:叶片振动疲劳寿命与稀土相颗粒的尺寸和分布位置具有密切关系.稀土相颗粒尺寸越大,对叶片振动疲劳裂纹的萌生作用也越大,疲劳寿命降低;外露于或镶嵌于叶片表面的稀土相颗粒明显促进了叶片振动疲劳裂纹的萌生.     

Influence of residual fatigue damage on the fracture toughness parameters of an AA6082-T6 aluminium alloy

The present investigation has been carried out in order to study the influence of the previous accumulated fatigue damage induced during high cycle fatigue (HCF), on the fracture toughness parameters of an AA6082-T6 aluminium alloy. The results show that previous fatigue damage accumulated in HCF does not affect the tensile static mechanical properties of the material, but gives rise to a significant debit of the toughness properties on this aluminium alloy. The fracture toughness results have shown that the crack opening displacement at a crack extension of 0.2 mm (COD_0.2) decreases in the range of ∼18 to 36% whereas the value of the non-linear fracture mechanics parameter  J _0.2, decreases in the range of ∼11 to 25% at applied maximum stresses of 200 and 275 MPa, respectively. Optical microscopy observations conducted on the surface of the specimens subjected to HCF damage indicate the existence of microcracks ∼15 to 25 μm long nucleated along the grain boundaries of the material. Also, the scanning electron microscopy (SEM) observations of the fracture surfaces after the tearing tests show the predominance of a ductile fracture mechanism for the material prior to residual fatigue damage, whereas a mixed ductile–brittle fracture mechanism and the presence of flat facets were observed on the fracture surfaces of the specimens with a fatigue damage of 0.70.     

Short fatigue crack propagation during low-cycle,high cycle and very-high-cycle fatigue of duplex steel – An unified approach

The present paper reviews experimental results on the fatigue damage of austenitic–ferritic duplex steel under various load levels ranging from LCF to VHCF, placing the focus towards the relationship between the crystallographic orientation of individual grains and grain patches that exhibit slip band formation, fatigue crack initiation and growth. A combination between fatigue testing of electropolished specimens and analytical electron microscopy (SEM/EBSD, TEM) revealed that under LCF loading conditions almost all the ferrite and the austenite grains showed plasticity, while under HCF and VHCF loading conditions, slip band formation was limited to the softer austenite grains and a low plastic activity is observed in the ferrite. Once being formed, the bands generate high stress concentrations, where they impinge the α–γ phase boundaries, eventually, leading to the crack initiation. This is discussed by applying a numerical simulation approach based on the finite-element (FEM) and the boundary-element (BEM) method.     

Low-cycle fatigue life prediction of a polycrystalline nickel-base superalloy using crystal plasticity modelling approach

A crystal plasticity model is developed to predict the cyclic plasticity during the low-cycle fatigue of GH4169 superalloy. Accumulated plastic slip and energy dissipation as fatigue indicator parameters(FIPs) are used to predict fatigue crack initiation and the fatigue life until failure. Results show that fatigue damage is most likely to initiate at triple points and grain boundaries where severe plastic slip and energy dissipation are present. The predicted fatigue life until failure is within the scatter band of factor 2 when compared with experimental data for the total strain amplitudes ranging from 0.8% to 2.4%.Microscopically, the adjacent grain arrangements and their interactions account for the stress concentration. In addition, different sets of grain orientations with the same total grain numbers of 150 were generated using the present model. Results show that different sets have significant influence on the distribution of stresses between each individual grain at the meso-scale, although little effect is found on the macroscopic length-scale.     

Total Fatigue Life Estimation of Notched Structural Components Using Low‐Cycle Fatigue Properties

Abstract: In this investigation, an efficient fatigue life computation method under variable amplitude loading of structural components has been proposed. Attention in this study is focused on total fatigue life estimation of aircraft structural components. Flat specimens with central hole made of quenched and tempered steel 13H11N2V2MF were tested as representatives of different structural components. Total fatigue life of these specimens, defined as sum of fatigue crack initiation and crack growth life, was experimentally determined. Specimens were tested by blocks of positive variable amplitude loading. Crack initiation life was computed using theory of low‐cycle fatigue (LCF) properties. Cyclic stress–strain curve, Masing’s curve and approximate Sonsino’s curve were used for determining stress–strain response at critical point of considered specimens. Computation of crack initiation life was realised using Palmgren–Miner’s linear rule of damage accumulation, applied on Morrow’s curves of LCF properties. Crack growth life was predicted using strain energy density method. In this method, the same LCF properties were used for crack initiation life and for crack growth life computations also. Computation results are compared with own experimentally obtained results.     

Low-cycle fatigue characteristics and fracture behavior of the die-forged 2014 aircraft wheel

In order to provide a sufficient theoretical basis for the fatigue-resistant design of the aircraft wheels, strain-controlled low-cycle fatigue (LCF) tests were carried out on specimens machined in the extrusion direction (ED) and transverse direction (TD) of die-forged 2014 aluminum alloy wheels. Although the TD specimens have lower tensile strength and yield strength, the fatigue test results show that the TD specimens have superior fatigue life compared with the ED specimens at total strain amplitudes of 0.5–0.8%. This is predominantly caused by the coarse Al₁₂(MnSi)₂(FeCu) intermetallic particles close to the surface layer, which results in a relatively short crack initiation stage for the ED specimens. In contrast, TD specimens with finer and more uniform recrystallized grains exhibit more excellent resistance to fatigue crack initiation (FCI) and propagation (FCP). Moreover, the fatigue life of alloys could be accurately predicted via a Manson–Coffin–Basquin (MCB) model based on total strain.     

The influence of defect and temperature on the fatigue behaviours of Al‐Si‐Cu‐Mg‐Ni alloy

High‐cycle fatigue (HCF) properties of two Al‐Si‐Cu‐Mg‐Ni alloys with different defect sizes named as alloys A (smaller ones) and B (bigger ones) were investigated at 350°C and 425°C, respectively. The results indicate that fatigue strengths of both alloys decrease as the temperature increases. Fatigue cracks originated from pores and oxide films at both temperatures. They propagated preferentially through cracked matrix at 350°C and debonded interface and grain boundary at 425°C. Alloy A exhibits higher fatigue life and fatigue strength than alloy B at 350°C due to its smaller pore sizes. However, it has slightly worse fatigue properties than alloy B at 425°C because the fatigue crack initiation is controlled by oxide film at this temperature and is not affected by its size. This indicates that there is a transition of predominant initiation site from pores to oxide films when the temperature increases. The fatigue strength estimated through defect size is consistent with the experimental results at 350°C, while unsuitable at 425°C.     

A notch critical plane approach of multiaxial fatigue life prediction for metallic notched specimens

An approach based on the local stress response is proposed to locate the fatigue critical point for metallic blunt notched specimens under multiaxial fatigue loading. According to the stress analysis, both stress gradient and gradient of loading nonproportionality exist at notch root. The plane in the vicinity of the notch that passes through the fatigue critical point and experiences the maximum shear stress amplitude is defined as the critical plane for notch specimens (CPN). Furthermore, the Susmel's fatigue damage parameter is modified to assess fatigue life of notched components by combining CPN and the theory of critical distance (TCD). The multiaxial fatigue test of the thin‐walled round tube specimens made of Ni‐base alloy GH4169 is carried out to verify the above approaches. In addition, test data of two kinds of materials are collected. The results show that the maximum absolute error of the fatigue critical point is 9.6° and the majority of the predicted life falls within the three‐time scatter band.