Fatigue crack growth from handling surface anomalies in a nickel based superalloy at high temperature

Abstract

Aircraft engine manufacturers have to demonstrate that handling surface anomalies in sensitive areas of discs are not critical for in-service life of a component. Currently, the models used consider anomalies as long cracks propagating from the first cycle, which introduces a certain degree of conservatism when calculating the fatigue life of surface flaws. Preliminary studies have shown that the first stages of crack propagation from surface anomalies are responsible for the conservative results. Thus, the aim of the study is to characterize the crack propagation from typical surface anomalies and to establish a new crack growth model, which can account for the micro-propagation stage. To separate the effects of the geometry of the anomalies and the residual stress state after introduction of the surface flaws, two V-type anomalies are studied: scratches and dents. Different studies have shown that the residual stresses beneath the anomalies seem to control the fatigue life of samples exhibiting scratches and dents. In order to monitor the crack micro-propagation, a direct current potential drop technique, coupled with heat tints is used during fatigue tests at elevated temperature. Thermal treatments releasing the residual stresses are also used to decouple the effect of crack morphology and residual stresses.