Improvement of fatigue-crack growth resistance by grain-boundary reaction precipitates at high temperature

Effects of grain-boundary reaction precipitates on fatigue-crack growth rate were investigated using austenitic 21 wt% Cr-4 wt% Ni-9wt% Mn heat-resisting steel at 973 K in air. Grain boundaries were serrated by-the grain-boundary reaction precipitates. The crack growth rate was considerably decreased by these precipitates, especially at low crack growth rates. Fatigue cracks extended to the serrated grain boundaries or to the interface between the grain-boundary reaction nodule and the grain. Therefore, the cracks grew along zigzag paths, and brittle intergranular fracture was inhibited. The decrease in the fatigue-crack growth rate was explained by these changes in fracture mode.     

Effects of serrated grain boundaries on the crack growth in austenitic heat-resisting steels during high-temperature creep

The effect of serrated grain boundaries on creep crack growth is investigated using an austenitic 21Cr-4Ni-9Mn steel principally at 700° C. The relationship between the microstructure of specimens and the crack growth behaviour is discussed. The creep crack growth rate in the specimens with a surface notch is relatively reduced by serrated grain boundaries especially in the early stage of crack growth. The life of crack propagation in the specimens with serrated grain boundaries is longer compared with that of the specimens with straight grain boundaries. It is confirmed in the surface crack growth of smooth round bar specimens crept at 700° C that serrated grain boundaries are effective in retarding the growth of a grain-boundary crack less than about 4×10^–4 m long, and that this effect decreases with increasing crack length. It is suggested that crack deflection due to serrated grain boundaries caused a decrease in the stress intensity factor of the grain-boundary crack and resulted in a decrease of the crack growth rate in the steel. The crack arrest at the deflection points and the circumvention of crack path on the serrated grain-boundaries may also contribute to the retardation of the grain-boundary crack growth during creep. Further, it is deduced from the experimental results on the notched specimens that the creep fracture is caused by the linkage of the main crack to many microcracks and voids on the grain-boundary at 900°C.     

Grain boundary engineering of titanium-stabilized 321 austenitic stainless steel

Grain boundary engineering (GBE) primarily aims to prevent the initiation and propagation of intergranular degradation along grain boundaries by frequent introduction of coincidence site lattice (CSL) boundaries into the grain boundary networks in materials. It has been reported that GBE is effective to prevent intergranular corrosion due to sensitization in unstabilized 304 and 316 austenitic stainless steels, but the effect of GBE on intergranular corrosion in stabilized austenitic stainless steels has not been clarified. In this study, a twin-induced GBE utilizing optimized thermomechanical processing with small pre-strain and subsequent annealing was applied to introduce very high frequencies of CSL boundaries into a titanium-stabilized 321 austenitic stainless steel. The resulting steel showed much higher resistance to intergranular corrosion after sensitization subsequent to carbon re-dissolution heat treatment during the ferric sulfate–sulfuric acid test than the as-received one. The high CSL frequency resulted in a very low percolation probability of random boundary networks in the over-threshold region and remarkable suppression of intergranular corrosion during GBE.     

Weld decay-resistant austenitic stainless steel by grain boundary engineering

This paper presents an example of grain boundary engineering (GBE) for improving intergranular-corrosion and weld-decay resistance of austenitic stainless steel. Transmission and scanning electron microscope (TEM and SEM) observations demonstrated that coincidence site lattice (CSL) boundaries possess strong resistance to intergranular precipitation and corrosion in weld decay region of a type 304 austenitic stainless steel weldment. A thermomechanical treatment for GBE was tried for improvement of intergranular corrosion resistance of the 304 austenitic stainless steel. The grain boundary character distribution (GBCD) was examined by orientation imaging microscopy (OIM). The sensitivity to intergranular corrosion was reduced by the thermomechanical treatment and indicated a minimum at a small roll-reduction. The frequency of CSL boundaries indicated a maximum at the small roll-reduction. The corrosion rate was much smaller in the thermomechanical-treated specimen than in the base material for long time sensitization. The optimum thermomechanical treatment introduced a high frequency of CSL boundaries and the clear discontinuity of corrosive random boundary network in the material, and resulted in the high intergranular corrosion resistance arresting the propagation of intergranular corrosion from the surface. The optimized 304 stainless steel showed an excellent resistance to weld decay during arc welding.     

Creep rupture strength and grain-boundary sliding in austenitic 21 Cr-4Ni-9Mn steels with serrated grain boundaries

The effect of grain-boundary strengthening on the creep-rupture strength by modification of the grain-boundary configuration is studied using austenitic 21 Cr-4Ni-9Mn steel in the temperature range from 600 to 1000° C in air. Grain-boundary sliding is also examined on a steel with serrated grain boundaries during creep at 700° C. The improvement of creep-rupture strength by the strengthening of grain boundaries is observed at high temperatures above 600° C. The 1000 h rupture strength of steels with serrated grain boundaries is considerably higher than that of steels with straight grain boundaries, especially at 700 and 800° C. The strengthening by serrated grain boundaries is effective in retarding both the crack initiation and the crack propagation at 700° C, while it does not improve the life to crack initiation at 900° C. Grain-boundary sliding is considerably inhibited by the strengthening of grain boundaries at 700° C. The amount of it in steels with serrated grain boundaries is less than about one-third of that of steels with straight grain boundaries at the same creep strain. The stress dependence of grain-boundary sliding rate in the steady-state regime is also examined from the steels with these two types of grain-boundary configuration.     

Improvement of Intergranular Stress Corrosion Crack Susceptibility of Austenite Stainless Steel through Grain Boundary Engineering

Intergranular stress corrosion crack susceptibility of austenite stainless steel was evaluated through threepoint bending test conducted in high temperature water. The experimental results showed that the frequent and efficient introduction of low energy coincidence site lattice boundaries through grain boundary engineering resulted in an apparent improvement of the intergranular stress corrosion crack resistance of austenite stainless steel.     

Effect of grain boundary microstructure on fatigue crack propagation in austenitic stainless steel

The effect of grain boundary microstructure on fatigue crack propagation in austenitic stainless steel was investigated in order to control fatigue crack propagation. The fraction of low-Σ coincidence boundaries in specimens was controlled by thermomechanical processing. The specimen with the higher fraction of low-Σ boundaries (73%) showed the lower propagation rate of fatigue crack than the specimen with the lower fraction of low-Σ boundaries (53%). The ratio of intergranular fracture segments to the total crack length was lower for the specimen with the higher fraction of low-Σ boundaries. Moreover, the roles of grain boundaries in the fatigue crack propagation were investigated in connection with grain boundary microstructure, i.e., the character distribution and geometrical configuration of grain boundaries. It is evidenced that the approach to grain boundary engineering is applicable to controlling fatigue crack propagation in austenitic stainless steel.     

Threshold stress intensity factor and crack growth rate for stress corrosion cracking of simulated heat affected zone in caustic solution

The threshold stress intensity factor for stress corrosion cracking (K_Iscc) of the simulated heat affected zone (HAZ) of mild steel in caustic solution has been determined using circumferential notch tensile (CNT) technique. The HAZ microstructure produced upon manual metal arc welding of grade 250 steel was simulated over a length of 35 mm of CNT specimens, using a thermo-mechanical simulator. Inter- and trans-granular stress corrosion cracking has been confirmed using a scanning electron microscope. The results presented here validate the ability of CNT technique for the determination of K_Iscc of HAZ and Base metal. Crack growth rates have also been determined using CNT technique. Further, the effect of microstructures on K_Iscc and crack growth rate is discussed in the present study. The determined K_Iscc of Base metal and simulated heat affected zone in 30% caustic solution is 24 and 45 MPa m^1/2, respectively.     

Effects of orientation,stress and exposure time on short intergranular stress corrosion crack behaviour in sensitised type 304 austenitic stainless steel

Intergranular stress corrosion cracking (IGSCC) in austenitic stainless steels occurs at susceptible grain boundaries after sensitisation. In this study, the effects of test duration, static stress (applied and residual) and microstructure orientation on the developed populations of short crack nuclei are reported for a sensitised type 304 austenitic stainless steel in an acidified potassium tetrathionate (K₂S₄O₆) solution. The crack populations were analysed using the Gumbel distribution method, showing an increase in the characteristic crack lengths with increasing time and grain size. There is a weak, but measurable effect of stress on crack length. Tensile stress increases crack growth and compressive residual stresses introduced by surface machining are shown to be beneficial. A significant dependence on sample orientation is observed and this cannot be explained in terms of the bulk microstructure properties or characteristics, which showed no significant variations.     

Zusammenwirken von Spannungsrißkorrosion und Ermüdung bei der Schwingungsrißkorrosion eines hochfesten Stahles

Conjoint Action of Stress Corrosion Cracking and Fatigue on Corrosion Fatigue of a High Strength Steel The corrosion fatigue characteristics of a high strength, martensitic steel in 0.5 n NaCl solution is investigated with regard to the fatigue and stress corrosion cracking behaviour of the material. Test parameters are stress ratio and frequency, testing is carried out with fracture mechanics methods, the crack surfaces are examined fractographically. An analysis of the results reveals that corrosion fatigue in high strength steel is caused by fatigue or by stress corrosion cracking, depending on the kinetics of the two processes. Fatigue and stress corrosion cracking do not act cumulative or additive. Instead, the kinetically faster process causes crack advance. The crack growth characteristics are interpreted with respect to the fractographic appearance of the crack surfaces. Corrosion fatigue cracks propagate either intergranular relative to the prior austenite grain boundaries as stress corrosion cracks do or transgranular like fatigue cracks, depending on the crack growth rates of the two processes. Fatigue and stress corrosion cracking do not interact, at least in a measurable degree, because of the different crack path of the two fracture processes. Results can be assessed quantitatively with the “process competition model”.     

Characteristics of hydrogen-assisted intergranular fatigue crack growth in interstitial-free steel: role of plastic strain localization

The behavior of intergranular fatigue crack growth in an interstitial-free (IF) steel in a hydrogen environment was investigated at different frequencies. Focusing on the plastic strain localization, we observed details of the striation-like feature on the intergranular fracture surface, slip behavior around microvoids, and crystallographic orientation gradient underneath the fracture surface. It was determined that the intergranular fatigue crack growth mechanism in the IF steel is microvoid formation at the crack tip and subsequent coalescence with the crack. Moreover, it was found that the grain boundaries, acting as propagation paths, suffer from pre-damage arising from plastic strain localization near the grain boundaries even before the main crack propagates to a certain location. Therefore, fatigue cracks in a hydrogen environment easily propagate to the grain boundaries. The frequency dependence of fatigue crack growth in the hydrogen environment is significantly smaller than that in a low carbon steel, probably because of the frequency dependence of the pre-damage evolution behavior.     

Numerical simulation of intergranular and transgranular crack propagation in ferroelectric polycrystals

We present a phase-field model to simulate intergranular and transgranular crack propagation in ferroelectric polycrystals. The proposed model couples three phase-fields describing (1) the polycrystalline structure, (2) the location of the cracks, and (3) the ferroelectric domain microstructure. Different polycrystalline microstructures are obtained from computer simulations of grain growth. Then, a phase-field model for fracture in ferroelectric single-crystals is extended to polycrystals by incorporating the differential fracture toughness of the bulk and the grain boundaries, and the different crystal orientations of the grains. Our simulation results show intergranular crack propagation in fine-grain microstructures, while transgranular crack propagation is observed in coarse grains. Crack deflection is shown as the main toughening mechanism in the fine-grain structure. Due to the ferroelectric domain switching mechanism, noticeable fracture toughness enhancement is also obtained for transgranular crack propagation. These observations agree with experiment.     

Role of Poisson’s ratio mismatch on the crack path in glass matrix particulate composites

The hydrogen-related fracture propagation process in martensitic steel was investigated through crystallographic orientation and fracture surface topography analyses. The hydrogen-related fracture surface consisted of three typical surfaces, namely smooth surfaces, surfaces with serrated markings, and surfaces with dimples. Crystallographic orientation analysis suggested that the smooth surface was generated by intergranular fracture at prior austenite grain boundaries, and the surface with serrated markings originated from quasi-cleavage fracture propagated along \(\{011\}\) planes. According to the reconstructed fracture propagation process by fracture surface topography analysis, the intergranular fracture at prior austenite grain boundaries initiated and propagated suddenly at the early stages of fracture. The quasi-cleavage fracture along \(\{011\}\) planes then gradually propagated within the prior austenite grains. At the final stages of fracture, ductile fracture accompanied by dimples occurred around the edge of the specimen. The results clearly indicated that the fracture propagation path changed with the proceeding fracture from the prior austenite grain boundaries to along \(\{011\}\) planes within the prior austenite grains.     

Influence of heat treatment on creep of a Mn–N stabilised austenitic stainless steel

Creep at 700 °C/196 MPa and 900 or 925 °C/27.4 MPa of 21Cr–4Ni–9Mn austenitic stainless steel is determined as a function of the heat treatment. The heat treatment variation involves altering the solution heat treatment cooling rate from water quenching to cooling at 6 or 4 °C/min causing: serrated grain boundaries versus planar grain boundaries, coarser intergranular carbides, and discontinuous precipitation of grain boundary reaction zones. Water quenching causes improved creep resistance. Creep fracture and cracking is intergranular. Coarse intergranular carbides and grain boundary reaction zones cause premature void formation and cracking, this damage leading to an accelerating creep rate and lowering creep resistance of the more slowly cooled conditions. During creep, grain boundary serrations, which may otherwise contribute to improved creep, are eliminated. Determining the individual influence of grain boundary serrations on creep requires a detailed investigation of various heat treatment parameters to prevent concurrent formation of grain boundary reaction zones and serrations.     

奥氏体不锈钢在石油精炼环境中应力腐蚀破裂

通过恒变形和恒载荷试验研究了敏化18—8型奥氏体不锈钢在连多硫酸介质中的应力腐蚀行为。研究表明,介质浓度在2.0～6.0％,PH 值在0.8～1.8范围是材料出现应力腐蚀破裂的敏感介质。断口分析表明,在该体系中破裂属晶间型。钢中晶界贫铬区的存在是产生晶间型应力腐蚀破裂的主要原因。     

Influence of grain boundaries on short crack growth behaviour of IGSCC

Understanding short crack behaviour is essential for predicting the lifetime of light water reactor components. However, crack growth rates of short cracks are unsteady due to microstructural obstacles such as grain boundaries. On the other hand, the statistical behaviour of short cracks can be deduced from crack size distributions. Some papers have pointed out that the crack size distributions obtained by stress corrosion cracking tests showed a kink in the distribution line. This kink suggests that the short crack growth rate is slow compared with that of long cracks. And it can be thought that the slow growth rate is caused by the microstructural obstacles. This study investigated the influence of grain boundaries on the short crack growth behaviour of intergranular stress corrosion cracking. A crack growth simulation model, which considered the mechanical effects of the crack kink and bifurcation by grain boundaries, was developed. The crack depth distribution obtained by the simulation also exhibited a kink in the distribution line as seen in the experimental results. This suggests that grain boundaries play an important role in short crack growth behaviour.     

Subcritical crack growth of trip steels in air under static loads

Pre-fatigued compact tension fracture toughness specimens of TRIP steel were held at constant loads at 25°C in 40 per cent r.h. air. Testing was done using an MTS closed loop universal test machine in the load control mode and the displacement was monitored as a function of time using a clip-on gauge and a strip chart recorder. Subcritical crack growth was observed and the experimental data was used to obtain a correlation between stress intensity and the rate of crack growth. The curves usually exhibited three distinct regions, including a plateau of stress intensity insensitive constant crack growth rates which have been observed by other investigators for titanium alloys and high strength steels. Based on comparisons with other investigators, the mechanism of subcritical flaw growth was tentatively identified as being due to hydrogen embrittlement. Fracture was observed to follow austenite grain boundaries and it was hypothesized that the austenite → martensite transformation sensitizes them to hydrogen by causing a large strain accumulation to be accommodated at the boundaries resulting in a large dilatation. Metallography revealed that the crack growth rate decreased as the strain-induced martensite increased and this was attributed to crack tip blunting by plastic deformation due to the invariant shear of the transformation. There are thus two apparently competing processes in the subcritical flaw growth of TRIP steels. Fractography showed that numerous fracture micromechanisms were operative. The subcritical crack growth characteristics compared favorably with other high strength steels tested under almost equivalent conditions and an apparent threshold for subcritical growth in air was determined to occur at about 56 per cent of K_IC.     

Effects of high-temperature ageing on the creep-rupture properties of cobalt-base L-605 alloys

Effects of high-temperature ageing on the creep-rupture properties of cobalt-base L-605 alloys were investigated at 1089 and 1311 K in air. The specimens with serrated grain boundaries and those with normal straight grain boundaries were aged for 1080ksec at 1273 or 1323 K to cause the matrix precipitates of tungsten-rich b c c phase and M₆C carbide. The creep-rupture strength of both specimens were improved by the high-temperature ageing. The rupture strength at 1311 K was the highest in the specimens with serrated grain boundaries aged at 1273 K, while the specimens with straight grain boundaries aged at 1273 K of the highest matrix hardness had the highest rupture strength at 1089 K. The high-temperature ageing did not decrease the rupture ductility of specimens. The ruptured specimens with serrated grain boundaries exhibited a ductile grain-boundary fracture surface which consisted of dimple patterns and steps, regardless of whether high-temperature ageing was carried out. The fracture mode of the specimens with straight grain boundaries was changed from the brittle grainboundary fracture to the ductile one similar to that of the specimens with serrated grain boundaries by high-temperature ageing, since large grain-boundary precipitates which gave nucleation sites of dimples were formed during the ageing. The grain-boundary cracks initiated in the early stage of creep (transient creep regime) in both non-aged and aged specimens of L-605 alloys in creep at 1089 and 1311 K, although the time to crack initiation is shorter in the specimens with straight grain boundaries than in those with serrated grain boundaries. Thus, the period of crack growth and linkage occupied most of the rupture life. The strengthening mechanisms of the aged specimens were also discussed.     

High-temperature hydrogen resistance of stainless steels

At elevated temperatures, the influence of hydrogen on various mechanical characteristics of martensitic and disperse-hardened austenitic steels is different. The maraging steel has better characteristics of durability and plasticity and the critical values of static and cyclic crack resistance at temperatures of 450–600°K than the austenitic steel with intermetallic hardening. As a result of the intense temperature softening, its ultimate and yield strengths are much lower than for the austenitic steel. The austenitic steel has higher resistance in terms of the threshold value ∆K _th. At room temperature, the low-cycle fatigue limit proves to be most sensitive to the action of hydrogen, whereas at 673°K, the parameter K _fc for the maraging steel decreases.     

Validity of a new fracture mechanics technique for the determination of the threshold stress intensity factor for stress corrosion cracking (KIscc) and crack growth rate of engineering materials

A novel fracture mechanics technique has been employed for the determination of crack growth rate and threshold stress intensity factor for stress corrosion cracking (K_Iscc) using small circumferential notch tensile (CNT) specimens. The technique was applied successfully for testing SCC susceptibility of heat treated 4340 steel in sodium chloride (NaCl) solutions at room temperature. Crack growth rates have been determined at different stress intensity factors (K_I), and the K_Iscc has been determined to be 15 MPa m^1/2. The obtained K_Iscc value using CNT specimen was found to be very close to K_Iscc values obtained by others using standard specimens.