Vibration fatigue behavior and failure mechanism of Ni-based single-crystal film cooling hole structure under high temperature

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Film cooling hole structures significantly influence vibration fatigue performance of Ni-based single crystal turbine blades. This study investigates the vibration fatigue behavior and failure mechanism of film cooling hole structure of Ni-based single crystal superalloy at high temperature by using the plate specimens with film cooling holes. The vibration fatigue cracks are all initiated at the edge of the film cooling hole on specimen surface, and the macroscopic crack path is a straight line path. At the microscopic scale, the crack path at 850 °C is a Zigzag path, but the crack path at 980 °C still shows a straight line path. The crack initiation of the specimen shows the oxidation crack nucleation in the stress concentration area under the coupling effect of high temperature and alternating stress. The macroscopic crack propagation direction at high temperature depends on the stress gradient direction of the resolved shear stress. At the microscopic scale, the crack propagation at 850 °C is the dislocation slip-climb mechanism, and the crack propagation at 980 °C more inclined to produce only the dislocation climb mechanism. The vibration fatigue cracks have the temperature dependence. The high temperature environment promotes the activation of slip system and the enhancement of dislocation mobility, the microscopic raft structure promotes the crack propagation along the γ phase with a large number of dislocations, the oxidation crack promotes the oxygen to enter the alloy matrix, which accelerates the Mode-I crack propagation.