On the fatigue crack growth behavior of WC–Co cemented carbides: kinetics description,microstructural effects and fatigue sensitivity

The influence of microstructure and load ratio (R) on the fatigue crack growth (FCG) characteristics of WC–Co cemented carbides are studied. In doing so, five hardmetal grades with different combinations of binder content and carbide grain size are investigated. Attempting to rationalize microstructural effects, key two-phase parameters, i.e. binder thickness and carbide contiguity, are used. On the other hand, the effect of load ratio is evaluated from the FCG behavior measured under R values of 0.1, 0.4 and 0.7. Experimental results indicate that: (1) WC–Co cemented carbides are markedly sensitive to fatigue; and (2) their FCG rates exhibit an extremely large dependence on K_max. Furthermore, both fatigue sensitivity and relative prevalence of K_max over ΔK, as the controlling fatigue mechanics parameter, are found to be significantly dependent upon microstructure. As mean binder free path increases, predominance of static over cyclic failure modes diminishes and a transition from a ceramic-like FCG behavior to a metallic-like one occurs (conversely in relation to contiguity). Consequently, the trade-off between fracture toughness and FCG resistance becomes more pronounced with increasing binder content and carbide grain size. The observed behavior is attributed to the effective low ductility of the constrained binder and its compromising role as the toughening and fatigue-susceptible agent in hardmetals, the latter on the basis that cyclic loading degrades or inhibits toughening mechanisms operative under monotonic loading, i.e. crack bridging and constrained plastic stretching.     

Behavior of a submicrocrystalline aluminum alloy 1570 under conditions of cyclic loading

A study of the resistance to fatigue-crack growth in a submicrocrystalline alloy Al-6% Mg-0.3% Sc-0.4% Mn in combination with a precision analysis of the fracture surface of the samples has been performed. A comparison of crack resistance between coarse-grained and submicrocrystalline states of this alloy showed that only at the stage of near-threshold crack growth the velocity of fatigue-crack propagation in the submicrocrystalline state proves to be higher than that in the coarse-grained state. At the stage of linear crack growth, the fatigue-crack propagation becomes insensitive to the grain size. Upon transition to the stage of accelerated crack growth, the velocity of crack propagation in the submicrocrystalline alloy is retarded. A fractographic analysis of the fracture surface of the samples indicates that the retardation of the fatigue-crack growth in the submicrocrystalline alloy is connected with a gradual transition from the intercrystalline to the transcrystalline mechanism of fatigue fracture of the material.     

Fatigue mechanics of WC–Co cemented carbides

The fracture and fatigue behavior of a fine-grained WC–10 wt% Co hardmetal is investigated. Mechanical characterization included flexural strength and fracture toughness as well as fatigue limit and fatigue crack growth (FCG) behavior under monotonic and cyclic loads, respectively. Considering that fatigue lifetime of cemented carbides is given by subcritical crack growth of preexisting defects, a linear elastic fracture mechanics (LEFM) approach is attempted to assess fatigue life–FCG relationships for these materials. Following the experimental finding of an extremely high dependence of FCG rates on the applied stress intensity for the hardmetal studied, the LEFM analysis is concentrated, from a practical design viewpoint, on addressing the fatigue limit–FCG threshold correlation under infinite fatigue life conditions. Thus, fatigue limit associated with natural flaws is estimated from FCG threshold experimentally determined for large cracks under the assumptions that (1) similitude on the FCG behavior of small and large cracks applies for cemented carbides, and (2) critical flaws are the same, in terms of nature, geometry and size, under monotonic and cyclic loading. The reliability of this fatigue mechanics approach is sustained through the excellent agreement observed between estimated and experimentally determined values for the fatigue limit under the different load ratios investigated.     

Effect of Carbon Migration on Interface Fatigue Crack Growth Behavior in 9Cr/CrMoV Dissimilar Welded Joint

Fatigue crack growth (FCG) behavior of 9Cr/CrMoV dissimilar welded joint at elevated temperature and different stress ratios was investigated. Attention was paid to the region near the fusion line of 9Cr where carbon-enriched zone (CEZ) and carbon-depleted zone (CDZ) formed due to carbon migration during the welding process. Hard and brittle tempered martensite dominated the stress ratio-insensitive FCG behavior in the coarse grain zone (CGZ) of 9Cr-HAZ. For crack near the CGZ-CEZ interface, crack deflection through the CEZ and into the CDZ was observed, accompanied by an accelerating FCG rate. Compared with the severe plastic deformation near the secondary crack in 9Cr-CGZ, the electron back-scattered diffraction analysis showed less deformation and lower resistance in the direction toward the brittle CEZ, which resulted in the transverse deflection. In spite of the plastic feature in CDZ revealed by fracture morphology, the less carbides due to carbon migration led to lower strength and weaker FCG resistance property in this region. In conclusion, the plasticity deterioration in CEZ and strength loss in CDZ accounted for the FCG path deflection and FCG rate acceleration, respectively, which aggravated the worst FCG resistance property of 9Cr-HAZ in the dissimilar welded joint.     

Role of the grain-boundary phase on the elevated-temperature strength,toughness, fatigue and creep resistance of silicon carbide sintered with Al,B and C

The high-temperature mechanical properties, specifically strength, fracture toughness, cyclic fatigue-crack growth and creep behavior, of an in situ toughened silicon carbide, with Al, B and C sintering additives (ABC-SiC), have been examined at temperatures from ambient to 1500°C with the objective of characterizing the role of the grain-boundary film/phase. It was found that the high strength, cyclic fatigue resistance and particularly the fracture toughness displayed by ABC-SiC at ambient temperatures was not severely compromised at elevated temperatures; indeed, the fatigue-crack growth properties up to 1300°C were essentially identical to those at 25°C, whereas resistance to creep deformation was superior to published results on silicon nitride ceramics. Mechanistically, the damage and shielding mechanisms governing cyclic fatigue-crack advance were essentially unchanged between ∼25°C and 1300°C, involving a mutual competition between intergranular cracking ahead of the crack tip and interlocking grain bridging in the crack wake. Moreover, creep deformation was not apparent below ∼1400°C, and involved grain-boundary sliding accommodated by diffusion along the interfaces between the grain-boundary film and SiC grains, with little evidence of cavitation. Such unusually good high-temperature properties in ABC-SiC are attributed to crystallization of the grain-boundary amorphous phase, which can occur either in situ, due to the prolonged thermal exposure associated with high-temperature fatigue and creep tests, or by prior heat treatment. Moreover, the presence of the crystallized grain-boundary phase did not degrade subsequent ambient-temperature mechanical properties; in fact, the strength, toughness and fatigue properties at 25°C were increased slightly.     

Phase assemblage effects on the fracture and fatigue characteristics of magnesia-partially stabilized zirconia

A detailed investigation on the relationships between phase assemblage and fracture and fatigue characteristics of Mg-PSZ has been conducted. In doing so, three completely different microstructural conditions were first attained through different thermal treatments and then their flexural strength, fracture toughness and crack growth resistance and fatigue crack growth (FCG) behaviour were evaluated. The obtained results are discussed considering the interplay between microstructural features and dominant crack-microstructure interaction and its influence on the operation of given toughening and mechanical fatigue mechanisms for each phase assemblage studied. FCG resistance, under both sustained and cyclic loading, is found to be closely related to the corresponding fracture toughness of each phase assemblage. However, real mechanical fatigue effects are estimated to be, once they are rationalized with respect to particular environmental-assisted cracking behaviours, an exclusive function of crack path type. Finally, different cyclic fatigue mechanisms for Mg-PSZ are pinpointed depending upon the prevalent transgranular or intergranular FCG morphology.     

Equicohesion: Intermediate Temperature Transition of the Grain Size Effect in the Nickel-Base Superalloy PM 3030

The intermediate temperature transition of the grain size effect on the yield strength of PM 3030 is investigated using compression tests from room temperature to 1200 °C. It is found that grain boundary strengthening is strong at low temperature which is consistent with conventional Hall–Petch hardening. However, the grain boundary contribution to strength diminishes exponentially at intermediate temperature and vanishes at the equicohesion point. Above the equicohesion point, finer grain structure leads to material softening primarily due to grain boundary diffusion and deformation processes. Maximum softening occurs at T _soft-max which is about 70% of the melting point, then decreases logarithmically with further increase in temperature, and vanishes at the melting point. This can well be rationalized by the overwhelming dominance of volume diffusion over grain boundary diffusion at temperatures close to the melting point, which decreases the impact of grain size on material strength. An exponential transition from the Hall–Petch behavior to the diffusion-based behavior provides an overall better fit of test data as compared to a linear transition. This study provides a contribution to the understanding of equicohesion and variation of the grain size effect on material strength and can be particularly crucial for components used at intermediate temperature.     

Abnormal grain growth and grain boundary faceting in a model Ni-base superalloy

Normal or abnormal grain growth in a model Ni-base superalloy is observed to depend on the grain boundary structure when heat-treated in a solid solution temperature range above the solvus temperature (1150°C) of the γ′ phase. When heat-treated at 1200°C abnormal grain growth occurs and most of the grain boundaries are observed to be faceted by optical microscopy, transmission electron microscopy, and scanning electron microscopy at the intergranular fracture surface. Some of the grain boundary facet planes are expected to be singular corresponding to the cusps in the polar plot of the boundary energy against the inclination angle, and it is proposed that if these boundary segments move by a boundary step mechanism, the abnormal grain growth can occur. When heat-treated at 1300°C normal grain growth occurs, the grain boundaries are defaceted, and hence atomically rough. Normal growth is expected if the migration rate of the rough grain boundaries increases linearly with the driving force arising from the grain size difference. The correlation between the grain boundary structural transition and the growth behavior thus appears to be general in pure metals and solid solution alloys.     

Effect of temperature,strain rate and grain size on the mechanical response of Ti3SiC2 in tension

Tensile, relaxation and cycling loading–unloading tests indicate that the mechanical response of Ti₃SiC₂ has a strong dependence on temperature and strain rate, but a weak dependence on grain size. Loading at low temperatures, and/or high strain rates, results in elastic and anelastic deformation, followed by brittle fracture. Anelastic deformation in this regime can be attributed to the easy glide of dislocation into pileups during loading, and their run back during unloading. At high temperatures (≈1100–1200°C), and/or low (<10⁻⁵ s⁻¹) strain rates, the response is plastic. The resulting strain is elastic, anelastic and plastic. Even at 1200°C, intense stress-relaxation processes are observed, and a sizable fraction (≈13%) of the strain is anelastic. At intermediate temperatures and strain rates (transition regime) the mechanical response is controlled by simultaneous damage formation (microcracking) and localized plastic deformation. Combining the results obtained in this work with previous results, viz. tensile creep and strain transient dip tests, a deformation map that takes into account temperature, grain size and strain rate is defined.     

AZ31镁合金在高周疲劳过程中微观组织和孪晶演变特征

利用扫描电子显微镜（SEM）和电子背散射衍射（EBSD）技术研究了室温条件下AZ31镁合金在不同加载频率（3和30 Hz）和不同应力幅值（90,95,100,105,110 MPa）疲劳变形后的组织演变规律及断口形貌特征。结果表明：随着加载应力增加,基体内残余孪晶数量增加,残余孪晶主要以拉伸孪晶形式存在。随着应力幅值的增加晶粒逐渐细化,这是由于在循环过程中,拉伸孪晶演变诱导晶粒细化。随着应力幅值的增加,织构强度显著减弱,这与试样疲劳后的再结晶机制有关。通过对试样疲劳断口的分析,发现孪晶片层处容易引起裂纹萌生,随着应力的增加,试样中裂纹扩展区面积逐渐减小,在疲劳裂纹扩展区观察到明显的疲劳辉纹。最终断裂区表面粗糙,主要存在韧窝、撕裂脊以及二次裂纹等形貌。在最终断裂区可观察到韧窝,韧窝尺寸随着循环应力的增加,在较高加载频率下,韧窝的尺寸与数量均减小。     

Molecular dynamics study of diffusional creep in nanocrystalline UO2

We present the results of molecular dynamics (MD) simulations to study high-temperature deformation of nanocrystalline UO₂. In qualitative agreement with experimental observations, the oxygen sublattice undergoes a structural transition at a temperature of about 2200 K (i.e. well below the melting point of 3450 K of our model system), whereas the uranium sublattice remains unchanged all the way up to melting. At temperatures well above this structural transition, columnar nanocrystalline model microstructures with a uniform grain size and grain shape were subjected to constant-stress loading at levels low enough to avoid microcracking and dislocation nucleation from the grain boundaries (GBs). Our simulations reveal that in the absence of grain growth, the material deforms via GB diffusion creep (also known as Coble creep). Analysis of the underlying self-diffusion behavior in undeformed nanocrystalline UO₂ reveals that, on our MD timescale, the uranium ions diffuse only via the GBs, whereas the much faster moving oxygen ions diffuse through both the lattice and the GBs. As expected for the Coble-creep mechanism, the creep activation energy agrees well with that for GB diffusion of the slowest-moving species, i.e. the uranium ions.     

Discrete dislocation plasticity modeling of short cracks in single crystals

The mode-I crack growth behavior of geometrically similar edge-cracked single crystal specimens of varying size subject to both monotonic and cyclic axial loading is analyzed using discrete dislocation dynamics. Plastic deformation is modeled through the motion of edge dislocations in an elastic solid with the lattice resistance to dislocation motion, dislocation nucleation, dislocation interaction with obstacles and dislocation annihilation incorporated through a set of constitutive rules. The fracture properties are specified through an irreversible cohesive relation. Under monotonic loading conditions, with the applied stress below the yield strength of the uncracked specimen, the initiation of crack growth is found to be governed by the mode-I stress intensity factor, calculated from the applied stress, with the value of K_init decreasing slightly with crack size due to the reduction in shielding associated with dislocations near a free surface. Under cyclic loading, the fatigue threshold is ΔK-governed for sufficiently long cracks. Below a critical crack size the value of ΔK_I at the fatigue threshold is found to decrease substantially with crack size and progressive cyclic crack growth occurs even when K_max is less than that required for the initiation of crack crack growth in an elastic solid. The reduction in the fatigue threshold with crack size is associated with a progressive increase in internal stress under cyclic loading. However, for sufficiently small cracks, the dislocation structure generated is sparse and the internal stresses and plastic dissipation associated with this structure alone are not sufficient to drive fatigue crack growth.     

A plasticity-corrected stress intensity factor for fatigue crack growth in ductile materials

In this paper, a plasticity-corrected stress intensity factor range ΔK_pc is developed on the basis of plastic zone toughening theory. Using this new mechanical driving force parameter for fatigue crack growth (FCG), a theoretical correlation of Paris’s law with the crack tip plastic zone is established. Thus, some of the important phenomena associated with the plastic zone around the fatigue crack tip, such as the effects of load ratio R, overload and T stress on the FCG behavior, can be incorporated into the classical Paris’s law. Comparisons with the experimental data demonstrate that ΔK_pc as a single and effective mechanical parameter is capable of describing the effects of the load ratio, T stress and overload on the FCG rate. The FCG rate described as a function of ΔK_pc tested under a simple loading condition can also be used for other complex loading conditions of the same material.     

Cu-Cr-Zr合金的低周疲劳行为

通过室温低周疲劳(LCF)试验研究了Cu-Cr-Zr合金的低周疲劳性能和循环变形行为,利用电子背散射衍射、透射电镜和扫描电镜分别分析了合金循环变形前后的微观结构和疲劳断口。结果表明:Cu-Cr-Zr合金的弹性应变幅、塑性应变幅与断裂时的循环周次之间的关系可分别用Basquin和Coffin-Manson公式表示。Cu-Cr-Zr合金在高外加总应变幅(Δε_t/2=0.6%)的疲劳变形后期会出现循环硬化现象,循环变形组织为位错墙、位错团簇、亚结构胞状组织的混合结构,并且观察到了孪晶的形成。此外,所选材料在外加总应变幅为0.4%时的疲劳断口呈现多疲劳源特征,疲劳裂纹扩展区中观察到了大量的撕裂棱、韧窝、以及犁沟。     

Fatigue crack growth mechanism in cast hybrid metal matrix composite reinforced with SiC particles and Al2O3 whiskers

The fatigue crack growth (FCG) mechanism of a cast hybrid metal matrix composite (MMC) reinforced with SiC particles and Al₂O₃ whiskers was investigated. For comparison, the FCG mechanisms of a cast MMC with Al₂O₃ whiskers and a cast Al alloy were also investigated. The results show that the FCG mechanism is observed in the near-threshold and stable-crack-growth regions. The hybrid MMC shows a higher threshold stress intensity factor range, ΔK_th, than the MMC with Al₂O₃ and Al alloy, indicating better resistance to crack growth in a lower stress intensity factor range, ΔK. In the near-threshold region with decreasing ΔK, the two composite materials exhibit similar FCG mechanism that is dominated by debonding of the reinforcement–matrix interface, and followed by void nucleation and coalescence in the Al matrix. At higher ΔK in the stable- or mid-crack-growth region, in addition to the debonding of the particle–matrix and whisker–matrix interface caused by cycle-by-cycle crack growth at the interface, the FCG is affected predominantly by striation formation in the Al matrix. Moreover, void nucleation and coalescence in the Al matrix and transgranular fracture of SiC particles and Al₂O₃ whiskers at high ΔK are also observed as the local unstable fracture mechanisms. However, the FCG of the monolithic Al alloy is dominated by void nucleation and coalescence at lower ΔK, whereas the FCG at higher ΔK is controlled mainly by striation formation in the Al grains, and followed by void nucleation and coalescence in the Si clusters.     

Cyclic compression behavior of a Cu–Zr–Al–Ag bulk metallic glass

The cyclic compression behavior of a Cu₄₅Zr₄₅Al₅Ag₅BMG was investigated in order to elucidate the damage initiation and growth mechanisms. The present Cu₄₅Zr₄₅Al₅Ag₅ BMG was found to have a fatigue-endurance limit of 1418 MPa and fatigue ratio of 0.77. Fracture under cyclic compression occurred in a pure shear mode. The fracture surface forms an angle of 41° with respect to the loading axis. This angle was similar to the monotonic compressive fracture angle for the present BMG. The cyclic compression fracture surface displays a morphology nearly identical to the monotonic compression fracture surface. In addition to many shear bands and cracks, areas of “chipping” were commonly found on the outside surfaces of the fatigue specimens. An attempt was made to measure crack growth rates, and two types of crack growth behavior were found. With the first type, the growth rate decreased with cycles due to the decrease in the driving force for crack propagation. With the second type, the crack growth rate increased with cycles after chipped areas developed. The fatigue deformation process for BMGs under cyclic compression was carefully studied and rationalized.     

Effects of deformation-induced martensite and grain size on ductile-to-brittle transition behavior of austenitic 18Cr-10Mn-N stainless steels

Effects of deformation-induced martensite and grain size on ductile-to-brittle transition behavior of austenitic 18Cr-10Mn-(0.3∼0.6)N stainless steels with different alloying elements were investigated by means of Charpy impact tests and microstructural analyses. The steels all exhibited ductile-to-brittle transition behavior due to unusual brittle fracture at low temperatures despite having a face-centered cubic structure. The ductileto-brittle transition temperature (DBTT) obtained from Chapry impact tests did not coincide with that predicted by an empirical equation depending on N content in austenitic Cr-Mn-N stainless steels. Furthermore, a decrease of grain size was not effective in terms of lowering DBTT. Electron back-scattered diffraction and transmission electron microscopy analyses of the cross-sectional area of the fracture surface showed that some austenites with lower stability could be transformed to α’-martensite by localized plastic deformation near the fracture surface. Based on these results, it was suggested that when austenitic 18Cr-10Mn-N stainless steels have limited Ni, Mo, and N content, the deterioration of austenite stability promotes the formation of deformation-induced martensite and thus increases DBTT by substantially decreasing low-temperature toughness.     

Analytical and computational description of effect of grain size on yield stress of metals

Four principal factors contribute to grain-boundary strengthening: (a) the grain boundaries act as barriers to plastic flow; (b) the grain boundaries act as dislocation sources; (c) elastic anisotropy causes additional stresses in grain-boundary surroundings; (d) multislip is activated in the grain-boundary regions, whereas grain interiors are initially dominated by single slip, if properly oriented. As a result, the regions adjoining grain boundaries harden at a rate much higher than grain interiors. A phenomenological constitutive equation predicting the effect of grain size on the yield stress of metals is discussed and extended to the nanocrystalline regime. At large grain sizes, it has the Hall–Petch form, and in the nanocrystalline domain the slope gradually decreases until it asymptotically approaches the flow stress of the grain boundaries. The material is envisaged as a composite, comprised of the grain interior, with flow stress σ_fG, and grain boundary work-hardened layer, with flow stress σ_fGB. The predictions of this model are compared with experimental measurements over the mono, micro, and nanocrystalline domains. Computational predictions are made of plastic flow as a function of grain size incorporating differences of dislocation accumulation rate in grain-boundary regions and grain interiors. The material is modeled as a monocrystalline core surrounded by a mantle (grain-boundary region) with a high work hardening rate response. This is the first computational plasticity calculation that accounts for grain size effects in a physically-based manner. A discussion of statistically stored and geometrically necessary dislocations in the framework of strain-gradient plasticity is introduced to describe these effects. Grain-boundary sliding in the nanocrystalline regime is predicted from calculations using the Raj–Ashby model and incorporated into the computations; it is shown to predispose the material to shear localization.     

Microstructure and Room Temperature Compressive Deformation Behavior of Cold-Sprayed High-Strength Cu Bulk Material

This study investigated the room temperature compressive deformation behavior of Cu bulk material manufactured by cold spray process. Initial microstructural observation identified a unique microstructure with grain size of hundreds of nm in the particle interface area and relatively coarse grains in all other areas. Room temperature compressive results confirmed cold-sprayed Cu to have a yield strength of 340 MPa, which is similar to materials manufactured by severe plastic deformation process such as equal channel angular press. In addition, strain softening phenomenon, which is rarely found in room temperature compressive deformation, was observed. According to such unique characteristics, continuous microstructure evolution and surface fractures according to the strain (ε _t = 0.3/0.6/0.9) of the material were observed, and considerations were made for deformation and fracture behavior. Microstructural observation after compressive deformation confirmed that average grain size decreased as the strain increased, and the fraction of the low-angle boundary, which has an indirect relationship with dislocation density, showed a tendency to decrease in ε _t = 0.3-0.6 region where the strain softening phenomenon occurs. Based on the results described above, this study was able to identify the possibility of manufacturing cold-sprayed Cu bulk material for structural material and its room temperature deformation behavior.     

Experimental evidence for diffusion creep in the superplastic 3 mol% yttria-stabilized tetragonal zirconia

Although there have been numerous studies on the high temperature deformation characteristics of the superplastic 3 mol% yttria stabilized tetragonal zirconia (3YTZ), the rate controlling deformation mechanism has not been identified unambiguously. In the present study, experiments were conducted on 3YTZ at high stresses and at coarser grain sizes than used conventionally for superplasticity. The experimental results reveal, for the first time, an intragranular dislocation motion controlled high stress regime that is independent of the grain size. With a decrease in stress, there is a transition to a Newtonian viscous deformation regime consistent with Coble grain boundary diffusion creep. At sufficiently low stresses, or in materials with finer grain sizes, there is a further transition to a grain size dependent interface controlled deformation regime. Analysis of the experimental data suggests strongly that superplastic flow in 3YTZ occurs by an interface controlled deformation mechanism.