Short crack initiation and growth at 600 °C in notched specimens of Inconel718

The natural initiation and growth of short cracks in Inconel®718 U-notch specimens has been studied at 600 °C in air. U notches were introduced through broaching, and hardness traces and optical microscopy on cross-sections through the U notch broaching showed that the broaching process had introduced a deformed, work hardened layer. Fatigue tests were conducted under load control using a 1-1-1-1 trapezoidal waveform, on specimens with as-broached and polished U-notches. Multi-site crack initiation occurred in the notch root. Many of the cracks initiated at bulge-like features formed by volume expansion of oxidising (Nb,Ti)C particles. In unstressed samples, oxidation of (Nb,Ti)C particles occurred readily, producing characteristic surface eruptions. Scanning electron microscopy on metallographic sections revealed some sub-surface (Nb,Ti)C oxidation and localised matrix deformation around oxidised particles. A mechanism for crack initiation by carbide expansion during oxidation is discussed. Surface short crack growth rates in the notch root of polished specimens were measured using an acetate replica technique. Observed short-crack growth rates were approximately constant across a wide range of crack lengths. However, there was a transition to rapid, accelerating crack growth once cracks reached several hundred micrometers in length. This rapid propagation in the latter stages of the fatigue life was assisted by crack coalescence. Polishing the U-notch to remove broaching marks resulted in a pronounced increase in fatigue life

A comparison of high temperature fatigue crack propagation in various sub-solvus heat treated turbine disc alloys

The microstructure and fatigue performance of three sub-solvus heat treated nickel based disc superalloys for turbine disc applications are reported. The alloy variants studied are RR1000, N18 and Udimet 720 Low Interstitial (U720Li), with the latter tested both in a standard and large grain variant (LG). Their microstructures are examined in terms of grain and gamma prime size. Fatigue crack growth (FCG) rates for all materials at 650ºC show that RR1000 provides the best performance, followed by U720Li-LG, N18 and U720Li. In general, the failure modes become increasingly intergranular with increasing ?K. Some of the variations in FCG rate between the alloys are due to reduction in grain boundary oxidation processes with increased grain size, but more subtle interplays between grain boundary character, alloy composition and slip character are also importan

Effects of microstructures on fatigue crack initiation and short crack propagation at room temperature in an advanced disc superalloy

Fatigue crack initiation and early short crack propagation behaviour in two microstructural variants of a recently developed Low Solvus, High Refractory (LSHR) disc superalloy at room temperature has been investigated by three-point bending with replication procedure. The results shows that fine gained (FG) LSHR possesses higher fatigue life due to its better crack initiation resistance, limited crack coalescence and comparable Stage I crack propagation resistance to the coarse grained (CG) LSHR, although its resistance to Stage II crack propagation is inferior. Twin boundary (TB) cracking in the relatively large grains dominates the crack initiation process along with occasional crack initiation due to slip band cracking. Activation of the primary slip systems parallel to the TB at matrix and twin and high resolved shear stress associated with high Schmid factor (SF) are required for TB crack initiation. Cracks preferentially propagate along slip bands associated with high SF slip systems after initiation. But cracks also propagate along slip bands associated with slip systems with lower SF if the inclination angle between the slip band ahead of the crack tip and the crack segment of the crack tip is small enough to enable a steady transition (or non-deflected growth) of cracks across the grain boundary

Superplastic behaviour of AZ91 magnesium alloy processed by high– pressure torsion

An investigation has been conducted on the tensile properties of a fine–grained AZ91 magnesium alloy processed at room temperature by high pressure torsion (HPT). Tensile testing was carried out at 423 K, 473 K and 573 K using strain rates from 1×10–1 s–1 to 1×10–4 s–1 for samples processed in HPT for N = 1, 3, 5 and 10 turns. After testing was completed, the microstructures were investigated by scanning electron microscopy and energy dispersive spectroscopy. The alloy processed at room temperature in HPT exhibited excellent superplastic behaviour with elongations higher than elongations reported previously for fine–grained AZ91 alloy produced by other severe plastic deformation processes, e.g. HPT, ECAP and EX–ECAP. A maximum elongation of 1308 % was achieved at a testing temperature of 573 K using a strain rate of 1×10–4 s–1, which is the highest value of elongation reported to date in this alloy. Excellent high–strain rate superplasticity (HSRSP) was achieved with maximum elongations of 590 % and 860 % at temperatures of 473 K and 573 K, respectively, using a strain rate of 1×10–2 s–1. The alloy exhibited low–temperature superplasticity (LTSP) with maximum elongations of 660 % and 760 % at a temperature of 423 K and using strain rates of 1×10–3 s–1 and 1×10–4 s–1, respectively. Grain–boundary sliding (GBS) was identified as the deformation mechanism during HSRSP, and the glide–dislocation creep accommodated by GBS dominated during LTSP. Grain–boundary sliding accommodated with diffusion creep was the deformation mechanism at high test temperature and slow strain rates. An enhanced thermal stability of the microstructure consisting of fine equiaxed grains during deformation at elevated temperature was attributed to the extremely fine grains produced in HPT at room temperature, a high volume fraction of nano ?–particles, and the formation of ?–phase filaments

International Journal of Fatigue, Volume 54:Evaluating surface deformation and near surface strain hardening resulting from shot peening a tempered martensitic steel and application to low cycle fatigue

The plastic deformation resulting from shot peening treatments applied to the ferritic heat resistant steelFV448 has been investigated. Two important effects have been quantified: surface roughness and strainhardening. 2D and 3D tactile and optical techniques for determining surface roughness amplitude parametershave been investigated; it was found that whilst Ra and Sa were consistent, Sz was generally higherthan Rz due to the increased probability of finding the worst case surface feature. Three different methodsfor evaluating the plastic strain profile have been evaluated with a view to establishing the variation inyield strength near the surface of a shot peened component. Microhardness, X-ray diffraction (XRD) linebroadening and electron backscatter diffraction (EBSD) local misorientation techniques were applied toboth uniaxially deformed calibration samples of known plastic strain and samples shot peened at intensitiesvarying from 4A to 18A to establish the variation in plastic strain and hence the variation in yieldstrength. The results from the three methods were compared; XRD and EBSD profiles were found to bethe most similar with microhardness profiles extending much deeper into the sample. Changes in themeasured plastic strain profile after exposure to low cycle fatigue and the correlation of these changeswith the cyclic stress–strain behaviour of the material are also discussed with a view to assessing theimportance of the dislocation profile in component life assessment procedures. 2013 Elsevier Ltd. All rights reserved

Synchrotron radiation computed tomography for experimental validation of a tensile strength model for unidirectional fibre-reinforced composites

Synchrotron radiation computed tomography has been used to analyse fibre break accumulation in unidirectional composites loaded in tension. The data are compared to model predictions. The model only slightly overestimated the composite failure strain, but predictions of fibre break density were too high, which can be mainly attributed to errors in the Weibull distribution. Both the number and percentage of interacting fibre break clusters were under-predicted by the model. This was attributed to an underestimation of stress concentrations in the model. While the experimental observations revealed mainly co-planar clusters, the model predicted mainly diffuse clusters. The experiments showed that the clusters did grow any further after their formation, while the model predicted a gradual development. Both local and dynamic stress concentrations were hypothesised to be key features for further exploration. The discrepancies identified, inform suggestions for directions advancing the state-of-the-art strength models of UD composites

Fatigue crack shielding in plain bearings under large scale yielding

Multi-layered bearing systems used in the automotive industry show shielding and antishielding effects that reduce or amplify the crack driving force under large-scale yielding conditions. Using finite element analysis, it is shown that shielding in such systems results in path deflection and bifurcation despite the absence of mixed-mode loading. As the crack approaches a stiff layer, the tangential strains measured around a blunted crack tip model show a maximum corresponding to the direction of crack propagation. The distribution of such strains indicates the effect of shielding and the likelihood of the tip to deflect or bifurcate.The suitability of bi-layer and tri-layer bearing architectures is assessed through crack path and respective crack driving force prediction