通过激光束粉末床熔融技术添加制造的高扭曲度（>70%）和 HIP 致密化 IN718 超合金在 450°C 下的疲劳机理

IF 5.7 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2024-10-03 DOI:10.1016/j.ijfatigue.2024.108629

Marcus C. Lam , Carla M.C. Cruz , Alexis Loustaunau , Anthony Koumpias , Amberlee S. Haselhuhn , Andrew Wessman , Sammy Tin

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引用次数: 0

摘要

高温下的抗疲劳性对于通过激光束粉末床融合（PBF-LB）方法用 IN718 超合金增材制造的航空航天结构的认证至关重要。本研究采用了一种称为 RHSA 的多步骤超溶热处理工艺和热等静压 (HIP)，以尽量减少孔隙和脆性相。应力强度因子（△K）计算采用了 X 射线计算机断层扫描数据，形状因子则参考了有限元分析（FEA）研究，结果证实△K 被抑制在传统 IN718 临界值（∼5 MPa√m）以下，疲劳行为转为以晶粒结构为主。尽管孪晶边界（TB）比例很高（70%），但在450°C和R = 0.1条件下进行的疲劳测试显示出较低的散度。滑痕分析和高分辨率电子反向散射衍射（EBSD）显示，孪晶边界引起的应变集中只有在高△K时才变得突出，导致与加载方向成 45⁰ 角的裂纹。与高角度晶界（HAGBs）（30-40⁰）相比，随机取向的TBs角度更高（60⁰），可能增强了抗滑移性并提供了净强化效应，这可以解释沿断裂路径的TB%低于平均值的原因。这些见解表明，如果疲劳应力不过大，高 TB 百分比并非有害，从而减轻了 AM IN718 在缺陷最小化过程中对退火孪晶的担忧，并允许采用新工艺来提高 PBF-LB IN718 的抗疲劳性。

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Fatigue mechanisms at 450°C of a highly twined (>70%) and HIP-densified IN718 superalloy additively manufactured by laser beam powder bed fusion

Fatigue resistance at elevated temperatures is crucial for certifying aerospace structures additively manufactured by the laser beam powder bed fusion (PBF-LB) method with IN718 superalloy. This study employed a multi-step, supersolvus heat treatment process with hot isostatic pressing (HIP), called RHSA, to minimize pores and brittle phases. Stress intensity factor (△K) calculations using data from X-ray computed tomography and shape factors referencing finite element analysis (FEA) studies confirmed the suppression of △K below the threshold of conventional IN718 (∼5 MPa√m), shifting fatigue behavior to grain-structure-dominated. Despite a very high twin boundary (TB) fraction (>70%), fatigue tests at 450°C and R = 0.1 demonstrated low scatter. Slip trace analysis and high-resolution electron backscatter diffraction (EBSD) revealed that TB-induced strain concentration became prominent only at high △K, causing cracking at 45⁰ to the loading direction. The randomly oriented TBs with higher angles (60⁰) compared to high-angle grain boundaries (HAGBs) (30–40⁰) likely enhanced slip resistance and provided a net strengthening effect, which can explain the lower-than-average TB% along fracture paths. These insights suggest that a high TB fraction is not detrimental if fatigue stress is not excessive, alleviating concerns about annealing twins during defect minimization in AM IN718, allowing novel processes to improve fatigue resistance in PBF-LB IN718.

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来源期刊

International Journal of Fatigue 工程技术-材料科学：综合

CiteScore

10.70

自引率

21.70%

发文量

619

审稿时长

58 days

期刊介绍： Typical subjects discussed in International Journal of Fatigue address: Novel fatigue testing and characterization methods (new kinds of fatigue tests, critical evaluation of existing methods, in situ measurement of fatigue degradation, non-contact field measurements) Multiaxial fatigue and complex loading effects of materials and structures, exploring state-of-the-art concepts in degradation under cyclic loading Fatigue in the very high cycle regime, including failure mode transitions from surface to subsurface, effects of surface treatment, processing, and loading conditions Modeling (including degradation processes and related driving forces, multiscale/multi-resolution methods, computational hierarchical and concurrent methods for coupled component and material responses, novel methods for notch root analysis, fracture mechanics, damage mechanics, crack growth kinetics, life prediction and durability, and prediction of stochastic fatigue behavior reflecting microstructure and service conditions) Models for early stages of fatigue crack formation and growth that explicitly consider microstructure and relevant materials science aspects Understanding the influence or manufacturing and processing route on fatigue degradation, and embedding this understanding in more predictive schemes for mitigation and design against fatigue Prognosis and damage state awareness (including sensors, monitoring, methodology, interactive control, accelerated methods, data interpretation) Applications of technologies associated with fatigue and their implications for structural integrity and reliability. This includes issues related to design, operation and maintenance, i.e., life cycle engineering Smart materials and structures that can sense and mitigate fatigue degradation Fatigue of devices and structures at small scales, including effects of process route and surfaces/interfaces.