Short fatigue crack growth mechanism in Ni-Co based superalloy at elevated temperatures and in oxidative atmospheres

Abstract

In this study, to elucidate the oxidation effect on the short fatigue crack growth (SFCG) characteristics of Ni-Co based TMW-4M3 superalloy, fatigue tests were conducted at room/elevated temperature in air/vacuum and three-dimensional microscopic observation of the SFCs using a plasma focused ion beam – scanning electron microscope (PFIB – SEM) system. Fatigue lives tested under vacuum at elevated temperature were comparable to those at room temperature while those tested at elevated temperatures in air showed shorter fatigue life in higher stress regions and longer fatigue life in lower stress regions than the others. In situ observation of SFCs at elevated temperatures in air revealed SFCG deceleration in the small ΔK regions and acceleration in large ΔK regions. SFCs opening/closing behaviours at elevated temperatures measured by digital image correlation (DIC) showed the crack opening stress to be higher at elevated temperature in air, possibly due to oxide-induced crack closure. However, the crack closure effect did not fully explain the difference in FCG rate between room and elevated temperatures in air. Three-dimensional investigations revealed SFCs to form at elevated temperatures in air, showing straight transgranular FCG to be insensitive to microstructure in slow growth regions, and intergranular FCG to precede that in the surrounding material in fast growth regions, in contrast to microstructural SFCs features at room temperature. It appears that slow and straight unique SFCG at elevated temperatures might occur due to intermittent brittle fracture of oxides formed at the crack tip. This suggests a possible role of the oxide layer at the crack tip in broadening the plastic deformation distribution, thus contributing to FCGR deceleration.