Microstructural extremes and the transition from fatigue crack initiation to small crack growth in a polycrystalline nickel-base superalloy

The fatigue behavior of the nickel-base superalloy René 88 DT has been investigated at room temperature with fully reversed loading in an ultrasonic fatigue apparatus operating at a frequency close to 20 kHz. A characterization protocol based on the electron backscatter diffraction technique has been developed to identify the combination of microstructural features within crack initiation sites and surrounding neighborhoods that leads to the transition from initiation to early small crack growth. Surface grains that were more than three times the average grain size, that were favorably oriented for cyclic slip localization and that also contained Σ3 twin boundaries inclined to the loading axis were most favorable for fatigue crack initiation. Fatigue cracks subsequently grew in grain clusters within which grains are misoriented by less than 20° relative to the initiation grains. More highly misoriented neighboring grains resulted in crack arrest. The material characteristics that promote crack initiation and small crack growth exist only at the extreme tails of the microstructural distributions. The implications for modeling of fatigue life and fatigue life variability are discussed.     

镍基单晶合金复杂应力状态低周疲劳寿命预测

根据损伤应变能释放率的定义表达式，将各向同性材料应力二三轴性因子拓展到正交异性材料，定义了含有3个弹性常数的镍基单晶应力三轴性因子。用它修正Mises应变范围作为疲劳损伤参量，可以显著消除晶体取向和多轴载荷对疲劳寿命的影响。用损伤应变能释放率作为热力学广义力描述正交异性材料的疲劳损伤过程，引入取向函数和损伤驱动力循环特征参数反映晶体各向异性对疲劳损伤的非线性影响以及循环载荷的交变特性，提出了单晶合金低周疲劳损伤模型。利用CMSX-2镍基单晶合金薄壁圆筒试样的拉一扭循环载荷低周疲劳试验数据和DD3镍基单晶合金缺口试样的低周疲劳试验数据，运用多元线性回归分析方法拟合模型的材料常数，试验所得数据分别落在2．5倍和2．0倍偏差分布带内。     

Effect of deformation temperature on the microstructure developed in commercial purity aluminum processed by equal channel angular extrusion

Equal channel angular extrusion (ECAE) was used to deform samples of commercial purity aluminum (AA1050) to a strain of ∼8. The effect of extrusion temperature on the deformation microstructures was investigated over the range of 298–523 K. Transmission electron microscopy was used to characterize quantitatively the microstructural parameters, including grain size, shape and boundary misorientation.     

EFFECTS OF STRAIN RATIO ON THERMAL-MECHANICAL CYCLIC STRESS-STRAIN RESPONSE AND FATIGUE LIFE IN DS SUPERALLOY DZ125

The effects of strain ratio on thermal-mechanical cyclic stress-strain response and fatigue life in DS superaUoy DZ125 have been studied by performing tests at various strain ratio experiments, under strain-controlled and temperature cycling from 550 to 1000℃. It is shown that thermal-mechanical cyclic stress-strain response behavior not only depend on magnitude of strain, and temperature-loading phase angle, but also strain ratio. Fatigue life at strain ratio Rε=-0.3 is longer than that of strain ratio Rε=-1.0, under in-phase thermal-mechanical loading. However, Fatigue life at strain ratio Rε=-0. 3 is shorter than that of strain ratio Rε=-1. 0, under out-of-phasethe rmal-mechanical loading. The thermal-mechanical fatigue (TMF) damage model was discussed. Results of fractography show that fatigue, creep and oxidation damage always occur during TMF. The main damage mode depends on loading wave, strain ratio and magnitude of strain.     

锆合金在应变速率1000s~(-1)下动态压缩显微组织的演化规律(英文)

研究锆合金在应变速率1000s-1动态压缩条件下的显微组织演化规律。基于相同应变速率下多次撞击的方法实现锆合金动态压缩下4个不同的应变水平。在不同的应变水平下,应力—应变曲线具有明显的应变硬化效应,几乎观察不到明显的热软化效应。标定的晶粒边界图像表明,在不同的应变水平下,在变形组织内均可观察到大量的小角晶界,同时,小角晶界的数量和密度随着应变的增加而增多。除了在晶粒边界图像中观察到的小角晶界和大角晶界外,在不同的应变水平下还可观察到孪晶界。孪晶界的类型主要包括{10 1 2}、{11 2 1}拉伸孪晶和{11 2 2}压缩孪晶,且大多数孪晶界为{10 1 2}拉伸孪晶。随着应变水平的增加,变形组织中孪晶界的密度变化不明显。基于不同应变水平下变形组织的表征,提出了动态载荷下锆合金变形和演化过程。显微硬度测试表明,撞击试样的硬度随着应变的增加而逐渐增大,这主要与位错塞积引起的应变硬化有关。     

Fatigue crack growth behavior of a solid solution-strengthened nickel-base superalloy (Incoloy 825)

Fatigue crack growth behavior of a solid solution-strengthened nickel-base superalloy (Incoloy 825)* was investigated. The investigation also examined the influence of heat treatment on resultant microstructures and the near-threshold fatigue crack growth behavior. In addition, the influence of load ratios(R), material strength, and grain size on fatigue threshold was studied. Compact tension specimens prepared from Incoloy 825 with transverse-longitudinal (TL) orientation in the as-received, as well as two different heat treated conditions, were used. The heat treatment studies revealed a peak hardness condition after solution treatment at 1200 °C for 1/2 hr, followed by aging at 600 °C for 434 hr. Among all the heat treated conditions, the fatigue threshold was the highest and the near-threshold crack growth rate was lowest in this peak aged condition. Fatigue threshold values were observed to decrease with an increase in load ratio, whereas an increased grain diameter resulted in a higher fatigue threshold. An earlier mathematical model was found applicable to characterize the relationship between load ratio and fatigue threshold. Preferential etching of grain boundary suggests formation of a thin film of carbide precipitation along the grain boundary region in the aged specimens. This carbide precipitation facilitated intergranular crack growth in these samples, resulting in higher roughness-induced crack closure. The highest fatigue threshold in the peak aged condition can be attributed to this large roughness-induced crack closure process. Incoloy 825 is a trademark for products of Huntington Alloys, Inc.     

HIGH TEMPERATURE CRACK PROPAGATION AND FRACTUREOF SUPERALLOYS

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单、多轴混合加载下GH4169合金的高温疲劳特性

利用拉扭薄壁管疲劳试样,在应变控制拉扭循环加载下对高温合金材料GH4169的多轴循环特性进行了实验研究,高温疲劳实验过程中,采用单、多轴混合加载路径对薄壁管疲劳试件进行加载,通过连续记录拉与扭的应力响应值研究了变幅高温多轴疲劳特性,结果表明,在高温低周单、多轴混合疲劳块载荷加载下,试件的疲劳寿命与应力响应特性不但取决于应变加载路径,而且与加载路径的排列顺序和加载参数的大小有关。     

The mechanisms of thermal engineered laser shock peening for enhanced fatigue performance

Thermal engineered laser shock peening (LSP) is a technique combining warm laser shock peening (WLSP) with subsequent post-shock tempering treatment to optimize the surface strength and fatigue performance of metallic materials. This technique integrates the advantages of LSP, dynamic strain aging (DSA), dynamic precipitation (DP) and post-shock tempering to obtain optimized microstructures for extending fatigue life, such as nanoprecipitates and highly dense dislocations. In this work, AISI 4140 steel is used to evaluate the thermal engineered LSP process. The resulting microstructures as well as mechanical properties are studied under various processing conditions. The mechanism underlying the improvements in fatigue performance is investigated. It is found that the extended fatigue life is mainly caused by the enhanced cyclic stability of compressive residual stress as well as surface strength. This improved material stability and reliability are attributed to the enhanced dislocation pinning effect corresponding to the number density, size and space distribution of nanoprecipitates, which could be tailored by manipulating the WLSP processing conditions and by post-shock tempering. The effects of the precipitate parameters on the precipitation kinetics as well as on the dislocation pinning strength are discussed.     

Effect of Fatigue Behavior on Microstructural Features in a Cast Al-12Si-CuNiMg Alloy Under High Cycle Fatigue Loading

High cycle fatigue tests of a cast Al-12Si-CuNiMg alloy are carried out under different stress amplitudes at room temperature. The scanning and transmission electron microscopy observations are used to examine the fracture surfaces and dislocation structures of the tested material, respectively. The results show that the fatigue damage originates from the microstructural defects, and the fracture surface morphology is typical quasi-cleavage fracture. With the increasing strain amplitude, the material fatigue life obviously decreases; however, the dislocation density increases significantly, which leads to the formation of the dislocation walls and cells. Under the cycle loading, the eutectic Si phase and the secondary particles undergo fracture. The pinning effect of the precipitates on the dislocations becomes obvious, indicating that the Al-12Si-CuNiMg alloy has the cyclic hardening characteristic.     

The fatigue response and fracture behavior of a spray atomized and deposited aluminum-silicon alloy

In this article the results of a recent study designed to improve our understanding of the cyclic fatigue and fracture characteristics of a spray atomized and deposited hypereutectic aluminum-silicon alloy are presented. Specimens of the alloy were cyclically deformed to failure at ambient temperature under fully reversed total strain amplitude controlled tension-compression loading. The alloy exhibited low cyclic plasticity and fatigue life under total strain amplitude controlled deformation. Cyclic stress amplitude controlled high-cycle fatigue characteristics were established at an elevated temperature (150 °C). The cyclic stress response, high-cycle fatigue life and fracture characteristics of the alloy are compared with a conventional ingot metallurgy processed counterpart and discussed in light of intrinsic microstructural features, nature and magnitude of stress, and ductility of the material.     

基于微结构分析定义应变路径非比例度

对316L不锈钢进行了单轴及多轴非比例循环加载低周疲劳实验及其微结构的观察，研究了非比例循环附加强化对应变路径依赖性的微观机理，分析了位错自由运动间距的分布规律．结果表明：316L不锈钢在非比例循环加载下产生的附加强化与材料中的多滑移位错结构的形态与尺寸直接相关，滑移面上的位错自由运动间距服从正态分布，位错自由运动间距的统计平均值与宏观等效饱和应力幅值之间呈现线性对数关系．基于上述研究结果，以位错自由运动间距统计平均值给出了应变路径非比例度的定义，结果表明：在单轴循环应力-应变关系式中引入新的非比例度的定义可以较好地描述应变路径对材料非比例循环变形行为的影响．     

A statistical investigation of the effects of grain boundary properties on transgranular fracture

A two-dimensional finite-element model is developed to investigate transgranular fracture in polycrystalline alumina under tensile loading. Microcracking is modeled explicitly using the cohesive interface approach. The effects of grain boundary distributions on mesoscopic failure strength and fracture energy, and the resulting percentages of transgranular fracture are examined. Results are based on 20 different realizations of microstructures in an attempt to capture the stochastic nature of brittle failure. Numerical results indicate that the grain boundary distribution has profound effects on mesoscopically observed values, which are in part controlled by the crack propagation path. Based on observations of the simulated crack path, microstructural engineering with respect to grain morphology is conducted, leading to a significant increase in performance.     

Fatigue in Ti–6Al–4V–B alloys

The addition of small amounts of B to Ti–6Al–4V alloy reduces the as-cast grain size by an order of magnitude and introduces TiB phase into the microstructure. The effects of these microstructural modifications on both the high cycle fatigue and cyclic stress–strain response were investigated. Experimental results show that B addition markedly enhances the fatigue strength of the alloy; however, the influence of prior-β grain size was found to be only marginal. The presence of TiB particles in the matrix appears to be beneficial with the addition of 0.55 wt.% B to Ti–6Al–4V enhancing the fatigue strength by more than 50%. Strain-controlled fatigue experiments reveal softening in the cyclic stress–strain response, which increases with the B content in the alloy. Transmission electron microscopy of the fatigued specimens indicates that generation of dislocations during cyclic loading and creation of twins due to strain incompatibility between the matrix and the TiB phase are possible reasons for the observed softening.     

Effect of Microstructure Instability on Hot Plasticity During Thermomechanical Processing in PM Nickel-Based SuperalloyEI北大核心CSCD

High alloying Ni-based powder metallurgy (PM) superalloys show excellent fatigue performance and damage tolerance properties, and good creep resistance at 750 degrees C, and are used for advanced gas turbine disks and other hot components. The hot-working window of high alloying PM superalloy is narrow because of its poor workability. The formation of the gamma+gamma' microduplex structure during the thermomechanical processing always results in a decrease in flow stress and a promotion of hot plasticity. However, the stability of the gamma+gamma' microduplex structure has not been evaluated. The high temperature flow behavior of a Ni-based superalloy FGH98 prepared by hot isostatic pressing has been examined by means of uniaxial compression testing isothermally at 1060, 1105, 1138 and 1165 degrees C and at constant true strain rates between 0.01 and 10 s(-1). The microstructural evolution and instabilities during plastic flow have been studied. Under all testing conditions, the as-hipped material exhibits flow hardening, flow softening and steady-state flow sequentially with the true strain increased. The dynamic recrystallization occurs and the gamma+gamma' microduplex structures are generated when steady state flow or highest strains achieved at temperatures below the g' solvus. The formation of the gamma+gamma' microduplex structures results in a remarkable decrease in grain size and a promotion of hot plasticity. The relationships between steady-state grain sizes and steady-state stresses during deformation and the formation mechanism of the gamma+gamma' microduplex structure were analyzed. The possibility of the microstructure controlling during hot working was discussed.     

Mechanical surface treatments of lightweight materials—Effects on fatigue strength and near-surface microstructures

Mechanical surface treatments such as shot peening or deep rolling are well-known processes to improve the fatigue strength of metallic components. This is due to favorable microstructural alterations in relatively thin surface layers as a consequence of near-surface inhomogeneous plastic deformations. Typical examples demonstrate the fatigue-strength increase for mechanically surface-treated specimens. Existing possibilities to improve the fatigue strength of welded joints by mechanical surface treatments are also included. In the case of lightweight materials (e. g. magnesium- or aluminum-base alloys), process parameters must be well adapted in individual cases to achieve optimum near-surface material states, taking into account the wide range of mechanical properties attainable as a result of their specific material microstructure. The effects of process parameters and microstructures on near-surface materials properties resulting from mechanical surface treatments are demonstrated with examples. Depth distributions of macroresidual and microresidual stresses are analyzed together with microstructural observations. An important point for the effectiveness of mechanical surface treatments is the stability of the near-surface material states during loading history. This aspect is treated for the case of fatigue loading.     

纯度对ECAP制备超细晶铜疲劳性能的影响

采用应力比R=–1的对称加载疲劳试验,研究了ECAP制备的超细晶高纯铜(HPCu)、低纯铜(LPCu)的疲劳行为,分析了循环应力-应变响应、疲劳寿命和疲劳前后晶粒取向分布,讨论了纯度与超细晶材料疲劳稳定性的关系。结果表明:在任何应力幅下,获得的超细晶低纯铜的寿命都大于ECAP变形前的粗晶铜;在相同应力幅下,循环周次提高1.6~2.0倍。而超细晶高纯铜的疲劳曲线,表现出不同的特性,在高应力幅下,超细晶高纯铜具有较高的疲劳寿命,但在低应力幅下,超细晶高纯铜循环周次下降,疲劳寿命低。在应力控制条件下,随应力幅的降低,超细晶纯铜的循环应力-应变响应从循环软化逐渐过渡为循环硬化。杂质的存在能有效阻止疲劳过程中晶粒的转动和位错的运动,降低其回复软化,减小相邻晶粒间取向差变化,使超细晶低纯铜与超细晶高纯铜相比有较大的循环硬化指数n和循环硬化系数K,具有较好的疲劳稳定性。     

Microstructure and evolution of mechanically-induced ultrafine grain in surface layer of AL-alloy subjected to USSP

Experiments were conducted to investigate the ultrafine-grained (UFG) microstructures in the surface layer of an aluminum alloy 7075 heavily worked by ultrasonic shot peening. Conventional and high-resolution electron microscopy was performed at various depths of the deformed layer. Results showed that UFG structures were introdued into the surface layer of 62 μm thick. With increasing strain, the various microstructural features, e.g., the dislocation emission source, elongated microbands, dislocation cells, dislocation cell blocks, equiaxed submicro-, and nano-crystal grains etc., were successively produced. The grain subdivision into the subgrains was found to be the main mechanism responsible for grain refinement. The simultaneous evolution of high boundary misorientations was ascribed to the subgrain boundary rotation for accommodating further strains. Formed microstructures were highly nonequilibratory.     

DAMAGE MECHANISMS OF INCONEL 738LC UNDER CREEP-FATIGUE LOADING CONDITIONS

1.IntroductionFirststagebladesofhigh--temperaturelandbasegasturbinesaredamagedbyacombinationofcreepandfatigue.Theleadingedgeofthebladeinparticularissubjectedtoacompressivestrainholdconditionduringgasturbineoperation.Suchconditionwasknownasthesevereconditionsfornickel-basedsuperalloysandsignificantreductionofcreep-fatiguelifehasbeenreported['--'].Althoughsomelifepredictionmethodsforsuchconditionshavebeenproposed[3],theyarenotsufficienttopredictthecreep--fatiguelifeingeneralduetolackofknowledgec…     

High-cycle fatigue of nickel-base superalloy René 104 (ME3): Interaction of microstructurally small cracks with grain boundaries of known character

High-cycle fatigue (HCF), involving the premature initiation and/or rapid propagation of small cracks to failure due to high-frequency cyclic loading, has been identified as one of the leading causes of turbine engine failures in aircraft. In this work, we consider the feasibility of using grain-boundary engineering to improve the HCF properties of a polycrystalline nickel-base superalloy, René 104 (also known as ME3), through systematic modification of the grain-boundary distribution. In particular, we investigate the growth of microstructurally small fatigue cracks at ambient temperature in microstructures with varying proportions of “special” vs. “random” boundaries, as defined by coincident-site lattice theory. Specifically, we examine the interaction of propagating small (∼10–900 μm) surface cracks with grain boundaries of known character, with respect both to any deflection in crack trajectory that occurs at or near the boundary, and more importantly to any local changes in crack-growth rates. In addition, finite-element calculations are performed to evaluate the effective driving force and plastic-zone profile for such small-crack propagation, incorporating information from both the local microstructure (from electron backscattering diffraction scans) and the surface crack-path profile.