A coupled CPFEM-CA-based method for predicting single crystal superalloy machining-induced static surface recrystallization depth

The aeroengine, the heart of the aircraft power system, is revered as the crown jewel of the aviation industry. As the material for aeroengine turbine blades, nickel-based single crystal (SX) superalloy leverages its single grain structure which is free from grain boundary defects, to enhance the aeroengine's power performance. During the manufacturing process of SX blades, the plastic deformation in machining process induces static surface recrystallization in high-temperature environment, accelerating fatigue crack propagation during service. Unfortunately, there is a lack of non-destructive methods for measuring or predicting the machining-induced recrystallization layer depth. In this paper, a simulation method based on the coupled crystal plasticity finite element and cellular automata (CPFEM-CA) approaches is proposed to predict the recrystallization layer depth in SX superalloys. The average error of the proposed method is 17.7 %. To the best of our knowledge, this method is the first to address the absence of SX superalloy machining-induced surface recrystallization non-destructive measurement.