An investigation of the fracture and fatigue crack growth behavior of forged damage-tolerant niobium aluminide intermetallics

The results of a recent study of the effects of ternary alloying with Ti on the fatigue and fracture behavior of a new class of forged damage-tolerant niobium aluminide (Nb₃Al-xTi) intermetallics are presented in this article. The alloys studied have the following nominal compositions: Nb-15Al-10Ti (10Ti alloy), Nb-15Al-25Ti (25Ti alloy), and Nb-15Al-40Ti (40Ti alloy). All compositions are quoted in atomic percentages unless stated otherwise. The 10Ti and 25Ti alloys exhibit fracture toughness levels between 10 and 20 MPa√m at room temperature. Fracture in these alloys occurs by brittle cleavage fracture modes. In contrast, a ductile dimpled fracture mode is observed at room-temperature for the alloy containing 40 at. pct Ti. The 40Ti alloy also exhibits exceptional combinations of room-temperature strength (695 to 904 MPa), ductility (4 to 30 pct), fracture toughness (40 to 100 MPa√m), and fatigue crack growth resistance (comparable to Ti-6Al-4V, monolithic Nb, and inconnel 718). The implications of the results are discussed for potential structural applications of the 40Ti alloy in the intermediate-temperature (∼700 °C to 750 °C) regime.     

Effects of temperature on the fatigue crack growth behavior of cast gamma-based titanium aluminides

This article reports the results of an experimental study of the effects of temperature (25 °C, 450 °C, and 700 °C) on the fatigue crack growth behavior of three near-commercial cast gamma titanium aluminide alloys (Ti-48Al-2Cr-2Nb, Ti-47Al-2Mn-2Nb+0.8 pct TiB₂, and Ti-45Al-2Mn-2Nb+0.8 pct TiB₂). The trends in the fatigue crack growth rate data are explained by considering the combined effects of crack-tip deformation mechanisms and oxide-induced crack closure. Faster fatigue crack growth rates at 450 °C are attributed to the high incidence of irreversible deformation-induced twinning, while slower crack growth rates at 700 °C are due to increased deformation by slip and the effects of oxide-induced crack closure.     

Fatigue and fracture behavior of a fine-grained lamellar TiAl alloy

The fatigue and fracture resistance of a TiAl alloy, Ti-47Al-2Nb-2Cr, with 0.2 at. pct boron addition was studied by performing tensile, fracture toughness, and fatigue crack growth tests. The material was heat treated to exhibit a fine-grained, fully lamellar microstructure with approximately 150-μm grain size and 1-μm lamellae spacing. Conventional tensile tests were conducted as a function of temperature to define the brittle-to-ductile transition temperature (BDTT), while fracture and fatigue tests were performed at 25 °C and 815 °C. Fracture toughness tests were performed inside a scanning electron microscope (SEM) equipped with a high-temperature loading stage, as well as using ASTM standard techniques. Fatigue crack growth of large and small cracks was studied in air using conventional methods and by testing inside the SEM. Fatigue and fracture mechanisms in the fine-grained, fully lamellar microstructure were identified and correlated with the corresponding properties. The results showed that the lamellar TiAl alloy exhibited moderate fracture toughness and fatigue crack growth resistance, despite low tensile ductility. The sources of ductility, fracture toughness, and fatigue resistance were identified and related to pertinent microstructural variables.     

Fatigue deformation of TiAl base alloys

The fatigue behavior of Ti-36.3 wt pct Al and Ti-36.2 wt pct Al-4.65 wt pct Nb alloys was studied in the temperature range room temperature to 900°C. The microstructures of the alloys tested consisted predominantly of γ phase (TiAl) with a small volume fraction of γ phase (Ti₃Al) distributed in lamellar form. The alloys were tested to failure in alternate tension-compression fatigue at several constant load amplitudes with zero mean stress. Fracture modes and substructural changes resulting from fatigue deformation were studied by scanning electron microscopy and transmission electron miscroscopy respectively. The ratio of fatigue strength (at 10⁶ cycles) to ultimate tensile strength was found to be in the range 0.5 to 0.8 over the range of temperatures tested. The predominant mode of fracture changed from cleavage type at room temperature to intergranular type at temperatures above 600°C. The fatigue microstructure at low temperatures consisted of a high density of a/3 [111] faults and dislocation debris of predominantly a/2 [110] and a/2 [110] Burger's vectors with no preferential alignment of dislocations. At high temperatures, a dislocation braid structure consisting of all 〈110〉 slip vectors was observed. The changes in fracture behavior with temperature correlated well with changes in dislocation substructure developed during fatigue deformation. S. M. L. SASTRY was formerly NRC Research Associate in the Air Force Materials Laboratory, Wright-Patterson Air Force Base, OH     

Influence of microstructure on crack-tip micromechanics and fracture behaviors of a two-phase TiAl alloy

The tensile deformation, crack-tip micromechanics, and fracture behaviors of a two-phase (γ + α₂) gamma titanium aluminide alloy, Ti-47Al-2.6Nb-2(Cr+V), heat-treated for the microstructure of either fine duplex (gamma + lamellar) or predominantly lamellar microstructure were studied in the 25 °C to 800 °C range.In situ tensile and fracture toughness tests were performed in vacuum using a high-temperature loading stage in a scanning electron microscope (SEM), while conventional tensile tests were performed in air. The results revealed strong influences of microstructure on the crack-tip deformation, quasi-static crack growth, and the fracture initiation behaviors in the alloy. Intergranular fracture and cleavage were the dominant fracture mechanisms in the duplex microstructure material, whose fracture remained brittle at temperatures up to 600 °C. In contrast, the nearly fully lamellar microstructure resulted in a relatively high crack growth resistance in the 25 °C to 800 °C range, with interface delamination, translamellar fracture, and decohesion of colony boundaries being the main fracture processes. The higher fracture resistance exhibited by the lamellar microstructure can be attributed, at least partly, to toughening by shear ligaments formed as the result of mismatched crack planes in the process zone.     

Effects of microstructure on the short fatigue crack initiation and propagation characteristics of biomedical α/β titanium alloys

This article presents the results of a study of the effects of microstructure on the fatigue strength and the short fatigue crack initiation and propagation characteristics of a biomedical α/β titanium alloy, Ti-6Al-7Nb. The results are compared to those obtained from a Ti-6Al-4V extra-low interstitial (ELI) alloy. Fatigue crack initiation occurs mainly at primary α grain boundaries in an equiaxed α structure, whereas, in a Widmanst?tten α structure, initiation occurs within the α colonies and prior β grains, where α plates are inclined at around 45 deg to the stress-axis direction. In an equiaxed α structure, the short fatigue crack initiation and propagation life, where the length of the crack (a) is in a microstructurally short fatigue-crack regime (2a < 50 μm), occupies around 50 pct of the total fatigue life. On the other hand, the fatigue crack in a Widmanst?tten α structure initiates at very early stages of fatigue, and, therefore, the fatigue crack-initiation life occupies a few percentages of the total fatigue life in an α structure. Then, the short fatigue crack propagates rapidly and is arrested at the grain boundaries of α colonies or prior β grains for a relatively long period, until the short crack passes through the boundaries to specimen failure. Therefore, the short fatigue crack-arrest life occupies more than 90 pct of the total fatigue life in a Widmanst?tten α structure. These trends are similar between the Ti-6Al-7Nb and Ti-6Al-4V ELI alloys and biomedical α/β titanium alloys. The total fatigue life for the Ti-6Al-7Nb alloy with an equiaxed α structure is changed by the volume fraction of primary α phase and the cooling rate after solution treatment. By increasing the volume fraction of the primary α phase from 0 to 70 pct, the fatigue limit of the Ti-6Al-7Nb alloy is raised. Changing the cooling rate after solution treatment by switching from air cooling to water quenching improves the fatigue limit of the Ti-6Al-7Nb alloy significantly.     

高铌TiAl合金的高温断裂韧性

利用紧凑拉伸试样通过预制疲劳裂纹研究近片层组织Ti-45Al-8Nb-0.2W-0.2B-0.1Y合金和全片层组织Ti-45Al-7Nb-0.2W-0.2Hf-0.3B-0.15C合金在750℃下的断裂韧性,并分析两种组织合金的断口形貌.结果表明,近片层组织和全片层组织高铌TiAl合金750℃时的断裂韧性分别为19.54和31.58 MPa·m1/2,且近片层组织疲劳裂纹开始萌生时的最大疲劳载荷明显低于全片层组织.断口分析表明近片层组织中裂纹主要在等轴γ晶中萌生,裂纹扩展方式包括沿γ晶、穿γ晶及沿片层、穿片层;全片层组织中裂纹主要在垂直于加载方向的片层间萌生,裂纹以沿片层与穿片层的混合方式进行扩展且伴有二次裂纹的萌生.      

Fatigue crack growth through alloyed niobium, Nb-Cr2Nb, and Nb-Nb5Si3 in situ composites

Fatigue cracks were grown through several niobium-based materials. For Nb-Cr-Ti composition materials, the single-phase alloy represented the matrix of two in situ composites with about 22 and 38 vol pct Cr₂Nb. Grain boundaries were coated with intermetallic in the lower-volume fraction material, while the 38 vol pct Cr₂Nb composite consisted of mainly spherical, dispersed intermetallic. The Nb-10Si composite was composed of about 28 vol pct primary Nb₅Si₃, with most of the matrix alloy in “fiberlike” shapes due to extrusion. Crack growth rates through the composites were generally faster than for unalloyed Nb, roughly in proportion to the volume fraction of intermetallic, although differences in microstructure make this comparison difficult. The presence of intermetallic greatly alters deformation of material near the crack tip. Particles of Cr₂Nb were broken during the crack growth process, leading to increased crack growth rates. These results suggest microstructural modifications that could be expected to enhance fatigue crack growth resistance.     

The Effect of Friction Stir Processing on the Mechanical Properties of Investment Cast and Hot Isostatically Pressed Ti-6Al-4V

Friction-stir (FS) processing was used to modify the coarse, fully lamellar microstructure of investment cast and hot isostatically pressed (HIP’ed) Ti-6Al-4V. The effect of FS processing on mechanical properties was investigated using microtensile and four-point bend fatigue testing. The tensile results showed a typical microstructure dependence where yield strength and ultimate tensile strength both increased with decreasing slip length. Depending on the processing parameters, fatigue strength at 10⁷ cycles was increased by 20 pct or 60 pct over that of the investment cast and HIP’ed base material. These improvements have been verified with a statistically significant number of tests. The results have been discussed in terms of the resistance of each microstructure fatigue crack initiation and small crack propagation. For comparison, a limited number of fatigue tests was performed on α + β forged Ti-6Al-4V with varying primary α volume fraction and also on investment cast material heat treated to produce a bi-lamellar condition.     

Effects of R-ratio on the fatigue crack growth of Nb-Si(ss) and Nb-10Si In Situ composites

The effects of changes in R ratio on the fatigue crack growth behavior of a Nb-10 at. pct Si composite as well as bulk Nb-1.24 at. pct Si were determined. Fatigue crack growth experiments were performed over a range of ΔK levels at R ratios of 0.1 and 0.4. Qualitative and quantitative scanning electron microscopy studies were performed to characterize the fatigue fracture features of the composites and alloys, in order to determine the factors controlling these fracture features. The results of this work indicate that increases in R ratio reduce the observed threshold stress intensities in both materials. Somewhat higher fatigue thresholds were observed in the Nb-Si _(ss) compared to pure Nb in the literature. In contrast to the bulk Nb-Si _(ss) alloy, which exhibited no evidence of cleavage fracture in fatigue at any R ratio or ΔK level, the Nb-Si _(ss) constituent in the Nb-10 at. pct Si composite exhibited a distinct fracture mode transition from ductile tearing near threshold and low ΔK to cleavage fracture with an increase in ΔK and K _max. Possible reasons for such observations are provided. This article is based on a presentation made in the symposium “Fatigue and Creep of Composite Materials” presented at the TMS Fall Meeting in Indianapolis, Indiana, September 14–18, 1997, under the auspices of the TMS/ASM Composite Materials Committee.     

Structure and properties of a β solution treated,quenched, and aged si-bearing near-α titanium alloy

The microstructure, tensile properties, and fractographic features of a near-α titanium alloy, IMI 829(Ti-6.1 wt pct Al-3.2 wt pct Zr-3.3 wt pct Sn-1 wt pct Nb-05 wt pct Mo-0.32 wt pct Si) have been studied after aging over a temperature range of 550°C to 950°C for 24 hours following solution treatment in the β phase field at 1050°C and water quenching. Transmission electron microscopy studies revealed that aging at 625°C and above produced discrete silicides at α′ interplatelet boundaries. However, aging at 900°C and above has also resulted in the precipitation of β phase along the lath boundaries of martensite. The silicides have been found to have a hexagonal structure withc=0.36 nm anda=0.70 nm (designated as S₂ by earlier workers). There is a significant improvement in yield and ultimate tensile strength after aging at 625°C, but there is less improvement at higher aging temperatures. The tensile ductility is found to be drastically reduced. While the fracture surface of the unaged specimen shows elongated dimples, the aged samples show a mixed mode of fracture, consisting of facets, featureless parallel bands, and extremely fine dimples.     

Effect of the Cr2Nb Phase on the Tensile Behavior and Oxidation Resistance of a Two-Step Heat-Treated Nb-24Ti-12Si-10Cr-2Al-2Hf Alloy

Metallurgical and Materials Transactions A - After a two-step heat treatment, the Cr2Nb particles in a directionally solidified Nb-24Ti-12Si-10Cr-2Al-2Hf (at pct, unless stated otherwise) alloy...     

Fracture and toughening mechanisms in an α2 titanium aluminide alloy

The deformation and fracture behaviors of the Ti-24Al-11Nb alloy with an equiaxed α₂ + β microstructure have been characterized as a function of temperature by performing uniaxial tension andJ _IC fracture toughness tests. The micromechanisms of crack initiation and growth have been studied bypost mortem fractographic and metallographic examinations of fractured specimens, as well as byin situ observation of the fracture events in a scanning electron microscope (SEM) equipped with a high-temperature loading stage. The results indicate that quasistatic crack growth in the Ti-24Al-11Nb alloy occurs by nucleation and linkage of the microcracks with the main crack, with the latter frequently bridged by ductile β ligaments. Three microcrack initiation mechanisms have been identified: (1) decohesion of planar slipbands in the α₂ matrix, (2) formation of voids and microcracks in β, and (3) cracking at or near the α₂ + β interface due to strain incompatibility resulting from impinging planar slip originated in α₂. The sources of fracture toughness in the 25 °C to 450 °C range have been attributed to crack tip blunting, crack deflection, and a bridging mechanism provided by the ductile β phase. At 600 °C, a change of toughening mechanisms leads to a lowering of the initiation toughness (theK _IC value) but a drastic increase in the crack growth toughness and the tearing modulus.     

An Investigation of the fracture behavior of gamma-based titanium aluminides: Effects of annealing in the α + γ and α2 + γ phase fields

The effects of annealing in the α + γ and α₂ + γ phase fields on the microstructures and fracture properties of Ti-48A1 and Ti-49Al-3.4Nb are discussed in this article. Annealing of the niobium-containing alloy in the α₂ + γ phase field results in the precipitation of ⇌₂ and Nb₅Si₃ predominantly at the grain boundaries. The precipitation decrease the grain boundary cohesion, thereby promoting intergranular separation. Precipitation also decreases the tensile strength and ductility of Ti-49Al-3.4Nb compared to that of the binary alloy. The possible role of interfaces in the transmission of slip is also discussed, and micromechanical models are applied to the prediction of tensile behavior and fracture toughness. Formerly Scientist, McDonnell Douglas Research Laboratories Formerly Director and MDC Fellow, McDonnell Douglas Research Laboratories     

Role of foreign-object damage on thresholds for high-cycle fatigue in Ti-6Al-4V

The increasing incidence of military aircraft engine failures that can be traced to high-cycle fatigue (HCF) has prompted a reassessment of the design methodologies for HCF-critical components, such as turbine blades and disks. Because of the high-frequency vibratory loading involved, damagetolerant design methodologies based on a threshold for no crack growth offer a preferred approach. As impact damage from ingested debris is a prime source of HCF-related failures, the current study is focused on the role of such foreign-object damage (FOD) in influencing fatigue crack-growth thresholds and early crack growth of both large and small cracks in a fan blade alloy, Ti-6Al-4V. FOD, which was simulated by the high-velocity (200 to 300 m/s) impact of steel spheres on a flat surface, was found to reduce markedly the fatigue strength, primarily due to earlier crack initiation. This is discussed in terms of four salient factors: (1) the stress concentration associated with the FOD indentation, (2) the presence of small microcracks in the damaged zone, (3) the localized presence of tensile residual hoop stresses at the base and rim of the indent sites, and (4) microstructural damage from FOD-induced plastic deformation. It was found that no crack growth occurred from FOD impact sites in this alloy at ΔK values below ∼ 2.9 MPa √m, i.e., over 50 pct higher than the “closure-free”, worst-case threshold value of ΔK _TH = 1.9 MPa √m, defined for large cracks in bimodal Ti-6Al-4V alloys at the highest possible load ratio. It is, therefore, concluded that such worst-case, large fatigue crack thresholds can, thus, be used as a practical lower-bound to FOD-initiated cracking in this alloy.     

Role of matrix microstructure on room-temperature tensile properties and fiber-strength utilization of an orthorhombic ti-alloy-based composite

Microstructure-property understanding obtained for a nominally Ti-25Al-17Nb (at. pct) monolithic sheet alloy was used to heat treat a unidirectional four-ply SCS-6/Ti-25Al-17Nb metal-matrix composite (MMC) and a fiberless “neat” material of the same alloy for enhancing mechanical properties. The unreinforced alloy and [0]₄ composite recorded significant improvements in ductility and strength, which were related to the microstructural condition. Modeling of the tensile strength based on fiber fracture statistics helped in understanding how improved matrix microstructure provided more efficient utilization of fiber strength. In comparison to the [0]₄ MMC, improvement of the [90]₄ response was negligible, which was related to an α₂ stabilized zone around the fiber. A Nb coating on the fiber was used to modify the local microstructure, and it produced a modest improvement in strength and ductility in the transverse direction. Structure-property relations of the matrix under different heat-treatment conditions are described in terms of deformation and failure mechanisms of the constituent phases; α₂ (ordered hexagonal close-packed), B2 (ordered body-centered cubic), and O (ordered orthorhombic based on Ti₂AlNb).     

Part III. The tensile behavior of Ti-Al-Nb O+Bcc orthorhombic alloys

The tensile behavior of Ti-Al-Nb alloys with Al concentrations between 12 and 26 at. pct and Nb concentrations between 22 and 38 at. pct has been investigated for temperatures between 25 °C and 650 °C. Several microstructural features were evaluated in an attempt to identify microstructure-property relationships. In particular, the effects of the phase volume fraction, composition, morphology, and grain size were examined. In addition, the constitutive properties were evaluated using single-phase microstructures, and the results provided insight into the microstructure-property relationships of the two-phase orthorhombic (O)+body-centered-cubic (bcc) microstructures. The disordered fully-bcc (β) Ti-12Al-38Nb microstructure, produced through heat treatment above the β-transus, exhibited a room-temperature (RT) elongation of more than 27 pct and the lowest yield strength (YS-553 MPa) of all the alloys studied. The ordered fully-bcc (B2) microstructures, produced through supertransus heat treatment of near-Ti₂AlNb alloys, exhibited fracture strengths up to 672 MPa and low elongations-to-failure (ε _f≤0.6 pct). Thus, increasing the Al content, which favors ordering of the bcc structure, significantly reduces the ductility of the bcc phase. Similar to the ordered B2 microstructure, the ordered fully-O Ti₂AlNb microstructures exhibited intermediate RT strength (≤704 MPa) and ε _f (≤1 pct). The O+bcc microstructures tended to exhibit strengths greater than both the fully-O and fully-bcc microstructures, and this was attributed to the finer grain sizes in the two-phase microstructures compared to their single-phase counterparts. A RT of 1125 MPa was measured for the finest-grained two-phase microstructure. The O+bcc microstructures containing greater bcc-phase volume fractions tended to exhibit greater elongations yet poorer elevated-temperature strengths. A higher Al content typically resulted in larger elevated-temperature strengths. For the Ti-12Al-38Nb bcc-dominated microstructures, fine O platelets, which precipitated during aging, provided significant strengthening and a reduction in ε _f for the Ti-12Al-38Nb alloy. However, large RT elongations (ε _f>12 pct) were maintained for aged Ti-12Al-38Nb microstructures, which contained 28 vol pct O phase. Morphology did not appear to play a dominant role, as fully-lath and fully-equiaxed two-phase microstructures containing the same phase volume fractions exhibited similar RT tensile properties. The slip and cracking observations provided evidence for the ductile and brittle characteristics of the single-phase microstructures, and the slip compatibility exhibited between the two phases is an important part of why O+bcc microstructures achieve attractive strengths and elongations. The YS vs temperature behavior is discussed in light of other Ti-alloy systems.     

The flow and fracture of a Ti3Al-Nb alloy

The deformation and fracture behavior of the titanium aluminide alloy Ti-24Al-11Nb (atomic percent) have been investigated over the temperature range of 27 °C to 500 °C. The alloy, which was examined in the “basket-weave” microstructural condition, deforms in a nonuniform manner and is characterized by plastically anisotropic flow on the scale of the prior beta grain size. As a consequence, locally severe strain incompatibilities develop near prior beta grain boundaries and contribute to microcrack initiation, which appears to be caused by a slip intersection process. The beta phase influences microcrack initiation as well as subsequent crack propagatio in both direct and indirect manners. Formerly with The Pennsylvania State University,.     

Effect of Stress Level on the High Temperature Deformation and Fracture Mechanisms of Ti-45Al-2Nb-2Mn-0.8 vol. pct TiB2: An In Situ Experimental Study

The effect of the applied stress on the deformation and crack nucleation and propagation mechanisms of a γ-TiAl intermetallic alloy (Ti-45Al-2Nb-2Mn (at. pct)-0.8 vol. pct TiB₂) was examined by means of in situ tensile (constant strain rate) and tensile-creep (constant load) experiments performed at 973 K (700 °C) using a scanning electron microscope. Colony boundary cracking developed during the secondary stage in creep tests at 300 and 400 MPa and during the tertiary stage of the creep tests performed at higher stresses. Colony boundary cracking was also observed in the constant strain rate tensile test. Interlamellar ledges were only found during the tensile-creep tests at high stresses (σ > 400 MPa) and during the constant strain rate tensile test. Quantitative measurements of the nature of the crack propagation path along secondary cracks and along the primary crack indicated that colony boundaries were preferential sites for crack propagation under all the conditions investigated. The frequency of interlamellar cracking increased with stress, but this fracture mechanism was always of secondary importance. Translamellar cracking was only observed along the primary crack.