Sensitive Temperature and Reason of Rapid Fatigue Crack Propagation in Nickel-Based Superalloy

doi:10.11900/0412.1961.2023.00151

Acta Metall Sin

2023, Vol. 59

Issue (9): 1190-1200 DOI: 10.11900/0412.1961.2023.00151

Research paper

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Sensitive Temperature and Reason of Rapid Fatigue Crack Propagation in Nickel-Based Superalloy

JIANG He, NAI Qiliang, XU Chao, ZHAO Xiao, YAO Zhihao, DONG Jianxin(

)

School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, China

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JIANG He, NAI Qiliang, XU Chao, ZHAO Xiao, YAO Zhihao, DONG Jianxin. Sensitive Temperature and Reason of Rapid Fatigue Crack Propagation in Nickel-Based Superalloy. Acta Metall Sin, 2023, 59(9): 1190-1200.

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Abstract

Superalloys are widely used in aerospace industry owing to the excellent mechanical properties and microstructure stability at high temperatures. However, the recent developments in the aerospace industry have piled higher demands on superalloys, especially for damage tolerance at high temperatures. The fatigue crack growth rate (FCGR) is an important parameter that describes damage tolerance. Although several domestic studies on FCGR in superalloys have been reported, systematic understanding is still lacking and urgently required. Hence, this study investigated the phenomenon of sensitive temperature for rapid fatigue crack propagation in several nickel-based superalloys and reasons for its emergence by adopting a systematic program of experiments and simulations. The fatigue crack propagation behavior of FGH4096, FGH4097, and FGH4098 powder-metallurgy nickel-based superalloys, and GH4720Li and GH4738 wrought nickel-based superalloys were systematically investigated in a wide temperature range of 550-800^oC using a fatigue crack propagation test. The fatigue crack propagation paths and crack microstructures after the fatigue crack propagation tests were observed. The results clearly demonstrated that the relationship between fatigue life and temperature is nonlinear. A sensitive temperature for rapid fatigue crack propagation for all investigated nickel-based superalloys was also observed, where the fatigue crack propagation rate markedly increased and fatigue life dramatically shortened. Microstructure evolution and mechanical property degradation at high temperatures were not found to be the major reasons behind the occurrence of sensitive temperature of rapid fatigue crack propagation. However, a comparison of fracture morphologies and fatigue crack propagation paths at different temperatures combined with the analysis of oxidation damage components revealed the high-temperature oxidation damage of grain boundary as the major reason for the occurrence of sensitive temperature. The contributions of fatigue damage and oxidation damage at different temperatures were compared using the classical linear superposition damage component model. The results showed that the contribution of oxidation damage increased markedly with increasing temperature. As a result, the fatigue life decreased dramatically at high temperatures and the fatigue propagation rates increased rapidly. Furthermore, the effect of O on the grain boundary strength in the Ni and NiCr system at different temperatures was investigated by molecular dynamics simulations. The grain boundary separation work decreased with increasing temperature and after which the value decreased dramaticalloy. It was concluded that the accumulation of O on the grain boundary resulted in a decrease in the grain boundary separation work and weakened the grain boundary.

Key words: nickel-based superalloy fatigue crack propagation sensitive temperature fatigue life

Received: 04 April 2023

ZTFLH:

TG146

Fund: National Natural Science Foundation of China(92160201)

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	JIANG He
	NAI Qiliang
	XU Chao
	ZHAO Xiao
	YAO Zhihao
	DONG Jianxin

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https://www.ams.org.cn/EN/10.11900/0412.1961.2023.00151 OR https://www.ams.org.cn/EN/Y2023/V59/I9/1190

Table 1 Chemical compositions of nickel-based superalloy used in present work

Fig.1 Schematic of compact tension (CT) specimen for fatigue crack propagation test (unit: mm)

Fig.2 Effects of temperature on fatigue propagation behavior of FGH4096 (a, b), FGH4097 (c, d), and FGH4098 (e, f) powder metallurgy superalloys
(a, c, e) da / dN-ΔK curves (da / dN—fatigue crack growth rate, ΔK—stress intensity factor range)
(b, d, f) fatigue crack growth lifetime (N) vs temperature

Fig.3 Effects of temperature on fatigue propagation behavior of GH4738 (a, b) and GH4720Li (c, d) wrought superalloys
(a, c) da / dN-ΔK curves (b, d) Nvs temperature

Fig.4 Low (a, c, e, g) and high (b, d, f, h) magnified SEM images of GH4720Li alloy after fatigue crack propagation test at 650^oC (a, b), 700^oC (c, d), 750^oC (e, f), and 800^oC (g, h) ( $γ I'$ —primary γ′ phase, $γ I I'$ —secondary γ′ phase, $γ I I I'$ —tertiary γ′ phase)

Table 2 Elastic modulus (E) and yield strength (σ_y) of GH4720Li alloy under different temperatures

Fig.5 Corrected da / dN-ΔK_norm curves of GH4720Li alloy (ΔK_norm—corrected ΔK)

Fig.6 SEM fracture images of FGH4098 alloy under 700^oC (a), 750^oC (b), and 800^oC (c) (Dashed lines in Figs.6b and c show the intergranular fracture mode turning point ΔK_T)

Fig.7 Fatigue crack propagation paths in CT sample of FGH4098 alloy under 700^oC (a) and 800^oC (b)

Fig.8 Fatigue crack propagation mechanism analyses of FGH4097 alloy at 650^oC (a), 700^oC (b), 750^oC (c), and 800^oC (d) ((da / dN)_F—fatigue damage component, (da / dN)_O—oxidation damage component, ΔK_e—load with equal fatigue and oxidation damage)

Fig.9 Schematic diagram of ΔK_e during fatigue crack propagation

Fig.10 Grain boundary model of Σ5[001](210)
(a) pure grain boundary (GB) model of Ni
(b) position of O in Ni model
(c) NiCr grain boundary model after disordered solution treatment

Fig.11 Effects of O concentration and temperature on grain boundary separation energy (W_sep)
(a) Σ5[001](210) grain boundary of Ni
(b) Σ5[001](210) grain boundary of NiCr
(c) comparison between Ni and NiCr

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