Oxidation and the Effects of High Temperature Exposures on Notched Fatigue Life of an Advanced Powder Metallurgy Disk Superalloy
Oxidation and the effects of high temperature exposures on notched fatigue life were considered for a powder metallurgy processed supersolvus heat-treated ME3 disk superalloy. The isothermal static oxidation response at 704 C, 760 C, and 815 C was consistent with other chromia forming nickel-based superalloys: a TiO2-Cr2O3 external oxide formed with a branched Al2O3 internal subscale that extended into a recrystallized - dissolution layer. These surface changes can potentially impact disk durability, making layer growth rates important. Growth of the external scales and dissolution layers followed a cubic rate law, while Al2O3 subscales followed a parabolic rate law. Cr- rich M23C6 carbides at the grain boundaries dissolved to help sustain Cr2O3 growth to depths about 12 times thicker than the scale. The effect of prior exposures was examined through notched low cycle fatigue tests performed to failure in air at 704 C. Prior exposures led to pronounced debits of up to 99 % in fatigue life, where fatigue life decreased inversely with exposure time. Exposures that produced roughly equivalent 1 m thick external scales at the various isotherms showed statistically equivalent fatigue lives, establishing that surface damage drives fatigue debit, not exposure temperature. Fractographic evaluation indicated the failure mode for the pre-exposed specimens involved surface crack initiations that shifted with exposure from predominately single intergranular initiations with transgranular propagation to multi-initiations from the cracked external oxide with intergranular propagation. Weakened grain boundaries at the surface resulting from the M23C6 carbide dissolution are partially responsible for the intergranular cracking. Removing the scale and subscale while leaving a layer where M23C6 carbides were dissolved did not lead to a significant fatigue life improvement, however, also removing the M23C6 carbide dissolution layer led to nearly full recovery of life, with a transgranular initiation typical to that observed in unexposed specimens.
Influence of orientation-dependent grain boundary oxidation on fatigue cracking behaviour in an advanced Ni-based superalloy
Fatigue tests have been conducted on an advanced disc Ni-based superalloy [low solvus, high refractory (LSHR) alloy] at 650 °C in air under three-point bend loading to investigate the role of orientation-dependent grain boundary (GB) oxidation in crack initiation and early propagation. It is found that crack initiation occurs mainly from bulged GB oxides, and cracks then predominantly propagate along the oxidised grain boundaries. These bulged oxides are extremely enriched in Co and preferentially form at the boundaries between high and low Schmid factor grains which are inclined normal to the applied tensile stress direction. Meanwhile, relatively flat/thin Ni/Ti/Al-rich oxide complexes also form at other grain boundaries, but they appear to be much less detrimental in fatigue crack initiation and propagation compared with the bulged GB Co-rich oxide complexes.
Microstructural characterisation and constitutive behaviour of alloy RR1000 under fatigue and creep–fatigue loading conditions
Abstract Mechanical behaviour of a nickel-based superalloy, RR1000, has been investigated at 650 °C under cyclic and dwell loading conditions. The microstructural characteristics of the alloy have been studied using scanning electron microscopy (SEM) and transmission electron microscopy (TEM), and the distribution patterns of the dislocations and slip planes have been compared between samples tested under fatigue and creep–fatigue loading conditions. Constitutive behaviour of the alloy was described by a unified constitutive model, where both cyclic plastic and viscoplastic strains were represented by one inelastic strain. The results show that the precipitation state is very stable at 650 °C and only minor differences exist in the dislocation arrangements formed under pure fatigue and combined creep and fatigue conditions. Hence, a unified constitutive model seems to be justified in describing and predicting the constitutive behaviour in both cases.