Temperature Effect-Related High and Very High Cycle Fatigue Failure Analysis and Life Estimation of Forged Superalloy

IF 4 3区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Metals and Materials International Pub Date : 2025-02-14 DOI:10.1007/s12540-025-01912-z

M. I. Lashari, W. Li, Z. F. Hu, C. Li, X. B. Cao, Y. Z. Jin

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Abstract

To analyze the temperature effect-related failure behavior and estimate the fatigue life of forged superalloy, high- and very-high-cycle fatigue experiments were performed. The microstructural characteristics, failure modes, and crack growth behavior are characterized by two- & three-dimensional microscopy techniques, along with electron-backscatter-diffraction (EBSD) analysis. The fractographic analysis demonstrated that surface failure at both 25 °C and 650 °C is attributed to surface flaws, whereas subsurface and internal failures are primarily driven by faceted cracking, often facilitated by inclusions or pores at 25 °C, and solely assisted by large grains at 650 °C. EBSD analysis revealed that crack propagation occurs in a transgranular manner, leading to the formation of facets; however, it is impeded by a complex structure comprised of high-angle grain boundaries and twin boundaries. In addition, under the influence of both temperatures, the threshold values for small as well as long cracks are elucidated. Finally, a fatigue life assessment approach that accounts for primary defects and different temperatures is established, and the prediction results demonstrate a closer alignment with the experimental data.

Graphical Abstract

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锻造高温合金高温高、甚高周疲劳失效分析及寿命估算

为了分析高温合金锻造过程中与温度效应相关的失效行为，估算其疲劳寿命，进行了高周疲劳试验和甚高周疲劳试验。利用二维三维显微技术和电子背散射衍射（EBSD）分析表征了材料的微观结构特征、失效模式和裂纹扩展行为。断口分析表明，在25°C和650°C时，表面破坏都是由表面缺陷造成的，而在25°C时，亚表面和内部破坏主要是由面裂驱动的，通常是由夹杂物或孔隙造成的，而在650°C时，大晶粒则是唯一的辅助因素。EBSD分析表明，裂纹扩展以穿晶方式发生，导致了切面的形成；然而，由高角度晶界和孪晶界组成的复杂结构阻碍了这一过程。此外，在两种温度的影响下，阐明了小裂纹和长裂纹的阈值。最后，建立了考虑原始缺陷和不同温度的疲劳寿命评估方法，预测结果与实验数据吻合较好。图形抽象

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来源期刊

Metals and Materials International 工程技术-材料科学：综合

CiteScore

7.10

自引率

8.60%

发文量

197

审稿时长

3.7 months

期刊介绍： Metals and Materials International publishes original papers and occasional critical reviews on all aspects of research and technology in materials engineering: physical metallurgy, materials science, and processing of metals and other materials. Emphasis is placed on those aspects of the science of materials that are concerned with the relationships among the processing, structure and properties (mechanical, chemical, electrical, electrochemical, magnetic and optical) of materials. Aspects of processing include the melting, casting, and fabrication with the thermodynamics, kinetics and modeling.