Abstract
Fatigue is a dominant failure mechanism of several engineering components. One technique for increasing the fatigue life is by inducing surface residual stress to inhibit crack initiation. In this review, a microstructural study under various bulk (such as severe plastic deformation) and surface mechanical treatments is detailed. The effect of individual microstructural feature, residual stress, and strain hardening on mechanical properties and fatigue crack mechanisms are discussed in detail with a focus on nickel-based superalloys. Attention is given to the gradient microstructure and interface boundary behavior for the mechanical performance. It is recommended that hybrid processes, such as shot peening (SP) followed by deep cold rolling (DCR), could enhance fatigue life. The technical and scientific understanding of microstructural features delineated here could be useful for developing materials for fatigue performance.
Highlights
The type of material and its physical, chemical, and mechanical properties determine the performance of a component during its period of operation
The SP treatment is widely used in aerospace industry as it is generally believed that the compressive residual stress (CRS) induced by shot peening may impede the crack initiation and propagation at the subsurface region, contributing to the enhanced fatigue performance [21]
Corresponding to these values, the high cycle fatigue (HCF) life of components has been increased by 32% in deep cold rolling, 35% in vibro peening, 61% in shot peening, and 66% in a combination of shot peening and vibro finishing in the IN718 HPC blisk aerofoils [5]
Summary
The type of material and its physical, chemical, and mechanical properties determine the performance of a component during its period of operation. Mechanical properties of engineering alloys may be dramatically compromised under severe operating conditions such as cyclic loading, vibrations [1], corrosive environments, and elevated temperatures [5] These conditions may lead to premature failure of the components during the service life. The SP treatment is widely used in aerospace industry as it is generally believed that the compressive residual stress (CRS) induced by shot peening may impede the crack initiation and propagation at the subsurface region, contributing to the enhanced fatigue performance [21]. A variety of surface mechanical treatments are compared based on the process intensity, residual stress distribution, microstructure, mechanical property, and fatigue performance. In angle/coherent/incoherent/twins), dislocation density, slip planes, residual stress on distribution, the last two sections, the microstructural features generated through various process routes such as strain hardening on fatigue life.
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