孙传文, 李伟(通讯作者), 孙锐. 激光增材镍基合金内部疲劳失效行为研究[J]. 工程科学学报. DOI: 10.13374/j.issn2095-9389.2024.01.27.001
引用本文: 孙传文, 李伟(通讯作者), 孙锐. 激光增材镍基合金内部疲劳失效行为研究[J]. 工程科学学报. DOI: 10.13374/j.issn2095-9389.2024.01.27.001
Investigation of the internal failure mechanism of laser additive manufactured nickel-based superalloy[J]. Chinese Journal of Engineering. DOI: 10.13374/j.issn2095-9389.2024.01.27.001
Citation: Investigation of the internal failure mechanism of laser additive manufactured nickel-based superalloy[J]. Chinese Journal of Engineering. DOI: 10.13374/j.issn2095-9389.2024.01.27.001

激光增材镍基合金内部疲劳失效行为研究

Investigation of the internal failure mechanism of laser additive manufactured nickel-based superalloy

  • 摘要: 内部失效是激光增材制造镍基高温合金在高温下的典型疲劳失效模式,目前对这种失效模式的认知尚不充分。在650 ℃下进行了不同应力比的轴向疲劳试验,随后采用扫描电镜、电子背散射衍射、聚焦离子束和透射电子显微镜等高通量测试技术,研究了增材制造镍基高温合金的多尺度内部失效行为。结果表明,不论是否受缺陷影响,微裂纹主要从晶粒取向较软的大晶粒处萌生,然后沿最大剪切应力方向滑移和扩展,形成晶体学小平面,因此与晶粒特征相关的小平面开裂是一种典型的内部失效模式。对小平面裂纹附近的位错结构进行分析,在650 ℃时,局部塑性变形是由反相边界剪切、沉淀物旁通以及堆积层错剪切机制的共同作用所引起的。结合裂纹尖端应力强度因子的定义,提出了与小平面裂纹特征相关的裂纹成核寿命预测方法,预测结果与实验结果具有较好的一致性。

     

    Abstract: Nickel-based superalloy exhibits excellent high strength and thermal fatigue resistance at 650 °C, and is therefore widely used in the manufacture of elevated temperature components such as turbine blades for aero-engines. Laser-powder bed fusion (L-PBF) is a rapidly developing metal additive manufacturing technology that is gradually becoming an important method for fabricating nickel-based superalloy products. The design and service life of aero-engine turbine blades usually require more than 107 load cycles, therefore, it is crucial to investigate the very high cycle fatigue characteristics of L-PBF nickel-based superalloy at elevated temperature. Internal failure is a typical elevated temperature fatigue failure mode of L-PBF nickel-base superalloy that is currently not well understood. To overcome this problem, firstly, axial fatigue tests with stress ratios of -1 and 0.1 are carried out at 650 ℃, and partial typical internal failure fractures at a stress ratio of 0.1 are selected as research objects. Secondly, scanning electron microscope and ultra depth field microscope are used to observe the 2D and 3D morphology of the fatigue fracture surface to analyze the crack nucleation area and growth path. The results show that, regardless of the presence of defects, the emergence and aggregation of a number of facets are observed in the "Facetted Cracking Area (FCA)", which is a typical internal failure characteristic of L-PBF nickel-based superalloy. Measurements show that the size of the facets leading to cracking is similar to the size of large grains and is related to differences in grain orientation. Therefore, internal failures are divided into two cracking modes: "defect-assisted faceted cracking" and "non-defect-assisted faceted cracking". Thirdly, the FCA with typical internal failure fractures is cut and subjected to electron backscatter diffraction analysis to observe the surface and subsurface crystallographic features of crack nucleation and growth behavior. The results show that microcracks mainly nucleate from large grains with softer grain orientation and then slip and expand along the direction of maximum shear stress, eventually exhibiting a perforated fracture pattern. Fourthly, subsurface microcrack features below the FCA are then observed in detail using focused ion beam milling and imaging, and slip band and dislocation structures in the vicinity of the microcracks are observed using transmission electron microscopy. The results confirm that the fatigue deformation mechanism of facet at 650 °C is mainly controlled by a combination of anti-phase boundary shearing, precipitate bypassing and stacking fault shearing, especially when subjected to stress concentration effects induced by cracks or defects. Finally, combined with the definition of the crack tip stress intensity factor, a crack nucleation life prediction method related to the characteristics of faceted cracks is proposed, and the prediction results are in good agreement with the experimental results.

     

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