Fatigue Small Crack Behavior of TiAl Alloys

doi:10.11900/0412.1961.2025.00367

Acta Metall Sin

2026, Vol. 62

Issue (5): 721-732 DOI: 10.11900/0412.1961.2025.00367

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Fatigue Small Crack Behavior of TiAl Alloys

XIANG Henggao¹^,²^,³, Song Weidong¹^,²^,³, JIA Luyi¹^,²^,³, QI Zhixiang¹^,²^,³, CHEN Yang¹^,²^,³(

), ZHOU Bing¹^,²^,³, ZHENG Gong¹^,²^,³, YING Pan¹^,²^,³, CHEN Guang¹^,²^,³

1 State Key Laboratory of Light Superalloys, Nanjing Research Base, Nanjing University of Science and Technology, Nanjing 210094, China
2 National Key Laboratory of Advanced Casting Technologies, Nanjing University of Science and Technology, Nanjing 210094, China
3 Nanjing Belight Laboratory, Nanjing 210094, China

Cite this article:

XIANG Henggao, Song Weidong, JIA Luyi, QI Zhixiang, CHEN Yang, ZHOU Bing, ZHENG Gong, YING Pan, CHEN Guang. Fatigue Small Crack Behavior of TiAl Alloys. Acta Metall Sin, 2026, 62(5): 721-732.

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Abstract

TiAl alloys are important lightweight materials for aerospace propulsion systems owing to their low density, creep resistance, corrosion resistance, and other properties. Fatigue is the primary failure mode of aeroengine blades. Once a long crack forms in a blade, rapid fracture can occur. The initiation and propagation of small fatigue cracks therefore directly determine the service life of blades. Focusing on the issue of small fatigue cracks in TiAl alloys, this paper systematically reviews the definition and characteristics of small fatigue cracks and summarizes the mechanisms of crack initiation and propagation in TiAl alloys. In addition, the propagation models of small fatigue cracks, together with their applicability and limitations, are discussed. Finally, future perspectives are presented regarding the characterization of fatigue small-crack initiation and propagation behavior and the development of unified life prediction methods for TiAl alloys.

Key words: TiAl alloy fatigue small crack initiation mechanism propagation mechanism prediction model

Received: 12 November 2025

ZTFLH:

TG146.2+3

Fund: National Natural Science Foundation of China(12202201);National Natural Science Foundation of China(52571145);National Natural Science Foundation of China(92463301);National Natural Science Foundation of China(52433016);National Natural Science Foundation of China(92163215);National Natural Science Foundation of China(52305379);National Natural Science Foundation of China(52174364);National Natural Science Foundation of China(52595663);Jiangsu Provincial Natural Science Foundation(BK20243066);Jiangsu Provincial Natural Science Foundation(BE2023024);State Key Laboratory of Light Superalloys(Sysjj2025203);State Key Laboratory of Light Superalloys(Sysjj2025101)

Corresponding Authors: CHEN Yang, professor, Tel: (025)84315159, E-mail: yang.chen@njust.edu.cn

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	Articles by authors
	XIANG Henggao
	Song Weidong
	JIA Luyi
	QI Zhixiang
	CHEN Yang
	ZHOU Bing
	ZHENG Gong
	YING Pan
	CHEN Guang

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00367 OR https://www.ams.org.cn/EN/Y2026/V62/I5/721

Fig.1 Fatigue crack propagation rates of small and long cracks^[10](a—crack length, N—number of cycles, ΔK—stress intensity factor range)

Fig.2 Surface-initiated fatigue small cracks in fully lamellar Ti-47Al-2Nb-2Cr-0.2B alloy^[33]
(a) initiation at the surface slip band (b) initiation at surface grain boundaries

Fig.3 Schematic of initiation and propagation of fatigue small cracks in Ti-46Al-4Nb-1.8Cr-0.2Ta alloy at the interface of lamellar colony^[37]

Fig.4 Schematic of small crack initiation positions in TiAl alloy

Fig.5 Relative numbers of small crack initiation sites in Ti-45Al-5Nb-0.2C-0.2B alloy under different lamellar orientations (θ)^[34]

Fig.6 Small crack growth rates of Ti-46.5Al-2.5V-1.0Cr alloy^[34]

Fig.7 Influences of tilt angle ( $β$ ) and twist angle ( $α$ ) of grain boundaries on small crack propagation behavior^[50]

Fig.8 Comparisons of fatigue crack propagation rates as a function of the ΔK (a) and effective stress intensity factor range (ΔK_eff) (b) under different stress ratios (R) in fully lamellar TiAl alloys^[21]

Fig.9 Schematics of small crack propagation hindered by interfaces in TiAl alloys
(a) grain boundary (b) twin boundary (c) lamellar boundary (d) lamellar colony boundary

Fig.10 Propagation growth rates of surface small cracks and long cracks in aluminum alloys based on the Newman model^[66] (S_max—maximum stress, σ₀—flow stress (average of yield strength (σ_ys) and ultimate tensile strength (σ_u)), K_T—stress concentration factor)

Fig.11 Prediction of 7075-T6 alloy crack propagation rate^[70]

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