Phasing effects on thermo-mechanical fatigue damage investigated via crystal plasticity modeling

Abstract

Nickel (Ni)-based superalloys have high strength at elevated temperatures, making them ideal candidates for aerospace components exposed to thermo-mechanical loads. Thermo-mechanical fatigue's (TMF) influence on material failure is highly dependent on the temperature-load phase profile as a consequence of path-dependent thermo-mechanical plasticity. In order to understand the direct influence phasing effects have on TMF performance, a microstructure-based fatigue model has been developed to connect damage mechanisms to crack initiation events. In this work, in-phase (IP) TMF, out-of-phase (OP) TMF, and iso-thermal (ISO) loading profiles are investigated with a temperature-dependent, dislocation density-based crystal plasticity model to pinpoint a relationship between microstructural damage and TMF phasing effects. A crystal plasticity modeling framework with capabilities to isolate phasing (IP, OP, and ISO) effects is presented to locate fatigue damage in a set of statistically equivalent microstructures (SEMs) with an energy-based damage indicative parameter. Local stress, accumulated damage, intragranular misorientiation, grain interactions, and slip alignment activity at the damaged regions are studied under the various temperature-load phase profiles to connect microstructural material damage to TMF performance. Based on the local microstructural material damage, it is postulated the material's stiffness at maximum load influences OP TMF performance, whereas the hardening/plasticity at maximum load influences IP TMF. The results from the presented framework is consistent with experimental evidence that at high mechanical strain amplitudes IP TMF has a shorter life as a consequence of hardening/plasticity influencing path-dependent thermo-mechanical plasticity, whereas at low strain amplitudes OP TMF has a shorter life due to stiffness influencing path-dependent thermo-mechanical plasticity.