Propagation Behaviors of Small Cracks in Powder Metallurgy Nickel-Based Superalloy FGH4096

doi:10.11900/0412.1961.2021.00221

Acta Metall Sin

2022, Vol. 58

Issue (5): 683-694 DOI: 10.11900/0412.1961.2021.00221

Research paper

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Propagation Behaviors of Small Cracks in Powder Metallurgy Nickel-Based Superalloy FGH4096

YANG Qinzheng¹, YANG Xiaoguang¹^,²(

), HUANG Weiqing³, SHI Duoqi¹^,²

^1.School of Energy and Power Engineering, Beihang University, Beijing 102206, China
^2.Beijing Key Laboratory of Aero-Engine Structure and Strength, Beihang University, Beijing 100191, China
^3.School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China

Cite this article:

YANG Qinzheng, YANG Xiaoguang, HUANG Weiqing, SHI Duoqi. Propagation Behaviors of Small Cracks in Powder Metallurgy Nickel-Based Superalloy FGH4096. Acta Metall Sin, 2022, 58(5): 683-694.

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Abstract

Inevitable nonmetallic inclusions (NMIs) exist in powder metallurgy (PM) superalloys. These inclusions serve as preferred sites for crack initiation either by fracture of inclusions or inclusion/matrix decohesion. After initiating from NMIs, fatigue cracks will experience the small crack propagation phase. Small fatigue cracks could grow under the fatigue crack growth threshold and propagate at a vibrated rate. To investigate the propagation behavior and reveal the underlying mechanisms, small crack propagation experiments under fatigue loads of different maximum stresses were conducted on PM superalloy FGH4096 using the small fatigue crack-propagation experiment system. The characterization of microstructure was conducted and orientations of grains were calibrated using SEM integrated with EBSD. Focusing on the three-dimensional nature and the physical basis, the propagation and stagnation behavior of small cracks were revealed. Experimental results showed that the small cracks propagated along octahedral slip planes, from initiation to a length even longer than 1.0 mm. During the propagation in the grain-containing twin, small cracks grew along the direction parallel to the twin boundary. However, several twin boundaries impeded crack growth. Small cracks were stagnated at grain and twin boundaries of which M factors were lower than adjacent ones. Three behaviors were observed after the stagnation of small cracks due to the different properties of grain/twin boundaries and the applied load; first, stagnated small cracks could continue to propagate by consuming more cycles; second, small cracks could propagate by alternating to another slip plane in current or other grains on the crack path; third, secondary cracks would initiate within 1-2 grains from the tip of the fully stagnated cracks and connected to the main crack. This behavior was observed only in the specimen in which the maximum stress is close to the lower limit of the yield strength.

Key words: powder metallurgy nickel-based superalloy small fatigue crack octahedral slip plane

Received: 21 May 2021

ZTFLH:

TG146

Fund: National Science and Technology Major Project(2017-IV-0012-0049);National Natural Science Foundation of China(51775019)

About author: YANG Xiaoguang, professor, Tel: (010)61716792, E-mail: yxg@buaa.edu.cn

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	Qinzheng YANG
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	Weiqing HUANG
	Duoqi SHI

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https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00221 OR https://www.ams.org.cn/EN/Y2022/V58/I5/683

Fig.1 Schematic of the geometry, and dimensions of the specimen and the micro-notch (unit: mm)

Fig.2 Schematic of the experimental system for small fatigue crack propagation (σ—loading, CCD—charge-coupled device camera)

Fig.3 Inverse pole figure (IPF) in Y direction (IPF-Y) coloring map (a) and the distribution of equivalent grain size (b) of FGH4096 superalloy

Fig.4 SEM images of the small crack in RH (a) and RL (b) specimens after the experiment

Fig.5 Stagnation of the left main crack and the initiation of the secondary crack in RL specimen recorded by the experimental system (a-c) and the associated SEM image (d) (N—number of cycle)
(a) the main crack was stagnated at N = 1.895 × 10⁵ cyc
(b) the secondary crack was initiated at N = 1.955 × 10⁵ cyc
(c) the secondary crack connected with the main crack at N = 2.005 × 10⁵ cyc
(d) SEM image of the main area in Figs.5a-c

Fig.6 Propagation of the right main crack and the initiation of the secondary crack in RL specimen recorded by the experimental system (a-c) and the associated SEM image (d)
(a) site of the main crack tip at N = 2.570 × 10⁵ cyc
(b) the secondary crack was initiated at N = 2.585 × 10⁵ cyc
(c) the secondary crack connected with the main crack at 2.595 × 10⁵ cyc
(d) SEM image of the main area in Figs.6a-c

Fig.7 IPF-Y colored SEM images of the crack path and the associated trace lines of {111} slip planes on the specimen surface in RH specimen
(a) the left crack path from N = 1.20 × 10⁴ cyc to N = 4.42 × 10⁴ cyc
(b) the left crack path from N = 9.052 × 10⁴ cyc to N = 9.268 × 10⁴ cyc

Fig.8 IPF-Y colored SEM images of the crack path and the associated trace lines of {111} slip planes on the specimen surface in RL specimen
(a) the right crack path from N = 5.550 × 10⁴ cyc to N = 1.085 × 10⁵ cyc
(b) the right crack path from N = 2.62 × 10⁵ cyc to N = 2.64 × 10⁵ cyc

Fig.9 IPF-Y colored SEM images of the small crack path that paralleled to the trace of twin grain boundary in RL specimen (a) or crossed the twin in RH specimen (b)

Table 1 Stagnation of the small cracks in RH and RL specimens

Fig.10 Schematics of two situations of the slip systems on both sides of the grain boundary when calculating M factor (Incoming slip plane—the slip plane in current grain, out-going slip plane—the slip plane in the grain in front of the grain boundary, n_in—the normal direction of incoming slip plane, n_out—the normal direction of out-going slip plane, $n 111$ , $n 1 ¯ 11$ , $n 1 1 ¯ 1$ , $n 1 ¯ 1 ¯ 1$ —the normal directions of ( $111$ ), ( $1 ¯ 11$ ), ( $1 1 ¯ 1$ ), and ( $1 ¯ 1 ¯ 1$ ) slip planes)
(a) the slip planes on both sides of the grain boundary are identified
(b) the slip plane in front of the grain boundary is uncertain, all 4 octahedral slip planes should be considered

Fig.11 IPF-Y colored SEM images of the stagnation sites and the associated trace lines of {111} slip planes on the specimen surface (a, c, e) of the small crack in RH specimen and the comparison of M factor (M_ab ) (b, d, f)
(a, b) stagnation site L1 (c, d) stagnation site L2 (e, f) stagnation site R1

Fig.12 IPF-Y colored SEM images of the stagnation sites and the associated trace lines of {111} slip planes on the specimen surface (a, c, e, g) of the small crack in RL specimen and the comparison of M factor (b, d, f, h)
(a, b) stagnation site L1 (c, d) stagnation site L2 (e, f) stagnation site R1 (g, h) stagnation site R2

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