In-phase Thermomechanical Fatigue Research Articles

Comparison of fatigue characteristics and failure analysis of Ni-based superalloy subjected to thermomechanical fatigue under different phase conditions

In this research, the thermomechanical fatigue (TMF) characteristics of a second-generation Ni-based single-crystal superalloy were investigated. The combined effects of temperature cycling and mechanical stress were examined using a strain-controlled approach under different TMF testing conditions. The results indicated that cyclic softening occurred during the early stages during in-phase (IP) loading. In contrast, out-of-phase (OP) tests exhibited cyclic hardening, as evidenced by an increase in the stress range, which intensified at higher mechanical strain amplitudes. This resulted in a shorter fatigue life compared to the IP TMF case. The crack distribution patterns and damage mechanisms on the cross-sectional and fracture surfaces of the failed specimens were analyzed. In the OP TMF tests, oxidation-assisted cracking was identified as the primary damage mechanism. The dominance of oxide layers was a key distinguishing feature. Additionally, twinning-related deformation and topologically close-packed (TCP) phase particles were observed in specimens subjected to a higher mechanical strain of 0.6%, where they ran parallel to the main crack, contributing to a reduction in lifetime. Conversely, the IP TMF cases were mainly dominated by creep damage mechanisms, with some signs of oxidation penetration observed during testing. The application of the Ostergren model to the fatigue life prediction of a Ni-based single-crystal superalloy under both conditions was evaluated. As this model was insufficient, a modified Ostergren model was proposed by incorporating the maximum and amplitude stresses in the power law forms.

Isothermal and thermomechanical fatigue crack growth behavior and modelling of 316LN stainless steel with the superposition of HCF loading

This work comparatively investigates the effect of superposition of high-cycle fatigue (HCF) loading on the crack growth behavior of 316LN stainless steel in isothermal fatigue (IF) and thermomechanical fatigue (TMF) tests. Results show that a deflection of the crack growth rate is observed in the tests without HCF loading. The superposition of HCF loading leads to a marked increase of crack growth rate in IF and out-of-phase TMF tests while a minimal variation in in-phase TMF test. Moreover, the crack growth rate in in-phase TMF test is smaller than the IF and out-of-phase TMF tests due to the different shape and evolution behavior of plastic zone at crack tip. Finally, the model based on the cumulative damage rule of time-dependent and cycle-dependent components is proposed, which considers the characteristics of plastic zone size and grain size and leads to a satisfactory prediction result.

A comparison of conventional and additively manufactured 316L under thermomechanical fatigue

The present study compares the thermomechanical fatigue (TMF) behaviour of 316L stainless steel manufactured conventionally by hot rolling and additively by laser powder bed fusion (L-PBF). Machined cylindrical specimens were tested under strain-controlled in-phase and out-of-phase TMF loading at a temperature range of 550–750 °C and total mechanical strain amplitudes of εamech = 0.2–0.6 %. While the conventional 316L significantly outperforms the L-PBF 316L under in-phase TMF, their lifetimes are comparable under out-of-phase TMF. Under in-phase TMF, creep damage in the form of intergranular crack networks occurs which is significantly more pronounced for the L-PBF 316L due to the higher amount of interfaces. Under out-of-phase TMF, the damage is mostly due to stress-assisted oxide cracking and the crack propagation is fatigue-dominated. TEM inspection revealed that L-PBF 316L exhibits a cellular dislocation structure in the initial state, which rearranges only slightly during cycling. For conventional 316L similar dislocation cells form during TMF cycling indicating that they represent a stable dislocation arrangement in 316L under TMF loading. This is evidenced by the rather stable cyclic stress response of the L-PBF material when compared to the conventional material.

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

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.

Experimental investigation of thermomechanical fatigue behavior in directionally solidified Ni-based superalloy under in-phase and out-of-phase conditions

The fatigue behavior of a directionally solidified (DS) Ni-based superalloy was investigated under in-phase (IP) and out-of-phase (OP) thermomechanical fatigue (TMF) conditions. Specimens were tested under strain control with a temperature range of 450–850 °C. In some tests, an optional 5 min out-of-phase dwell (OPD) time was introduced. In the case of IP TMF, the primary damage manifestation was predominantly intergranular cracks, whereas in the OP tests, the damage was mainly transgranular cracks. The fatigue life of IP TMF was found to be significantly shorter than that of OP TMF. This indicated that the intergranular cracks propagated faster than the transgranular cracks. The dwell time did not influence the dominant damage form; however, it led to an increase in the density of the microcracks. This increase resulted in a reduced lifetime, leading to lower stress amplitudes and higher plastic strain amplitudes compared with the continuous cycle tests. In addition, cycle hardening became apparent during the initial stages of cyclic loading. The microstructures and damage evolution were examined to provide insights into the changes in fatigue life. A model for predicting the fatigue life of DS Ni-based superalloy under given test conditions has been assessed. The proposed fracture mechanics model, which outlines the failure mechanism of directionally solidified Ni-based superalloy under TMF conditions, has proven to be effective in predicting fatigue life.

Investigation of damage mechanisms in thermomechanical fatigue of nickel-based single-crystal alloys

Thermomechanical fatigue (TMF) is essential for ensuring the safety and efficiency of various thermal engineering systems, however, the underlying damage mechanisms remain unclear. In the present work, a damage evolution model is used to quantify damage mechanisms in nickel-based single-crystal superalloy DD6. The isothermal creep-fatigue model combining the fatigue and creep damages is developed to elucidate their interactions and validated by the tension-dwelling experiments. Finally, the experimentally measured TMF damage is quantitatively decomposed into fatigue, creep and extra TMF components. Significant TMF damage in the in-phase TMF is identified, especially in the [001] specimens, potentially attributed to the non-isothermal creep or oxidation, while damage in out-of-phase TMF aligns with the spiking oxidation mechanism.

Deformation behavior and crack mechanism of a first generation single-crystal Ni-based superalloys under thermomechanical fatigue loading

A research investigation was conducted to analyze thermomechanical fatigue (TMF) in a first-generation nickel-based single-crystal superalloy. The analysis was conducted within a temperature range of 450–950 °C while employing a strain ratio of −1 during two phases, in-phase (IP) and out-of-phase (OP). TMF life data were collected at varying mechanical strain amplitudes. The IP and OP TMF lifetimes were compared under identical strain conditions. A detailed analysis of the fractures and microstructures of the tested specimens was performed to investigate the crack mechanism. In the IP specimens, the formation of cracks closely followed the direction perpendicular to the principal stress within the material, which was primarily associated with the presence of micropores. Internal cracks tended to develop at locations with strain concentrations and subsequently propagate outward from the surface. The main mechanism behind these cracks was the interaction between creep and fatigue damage. Conversely, in the OP TMF specimens subjected to an oxide scale formed on the fracture surface, leading to fatigue cracking at multiple locations. The cracks gradually extended within the material before transitioning into the (111) crystallographic planes, where localized deformation bands occurred, affecting an area depleted of the γ' phase. This crack mechanism predominantly involved interactions between oxidation and fatigue. Among the various fatigue life prediction models, the Ostergren model exhibited strong agreement with the predicted data points for the fatigue life.

Thermo-mechanical fatigue deformation and fracture mechanisms of nickel-based powder metallurgy superalloy

Thermo-mechanical fatigue (TMF) failure is one of the major concerns for aero-engine turbine discs under complex service loading conditions. By conducting both in-phase (IP) and out-of-phase (OP) TMF tests, the stress-strain hysteresis loops and the cyclic stress responses were analyzed for the third-generation nickel-based powder metallurgy (P/M) superalloy FGH4098. To reveal the failure mechanism, advanced microscopy analysis was carried out to characterize the fracture surface and microstructure of the alloy after failure. The phase angle between alternating mechanical and thermal loads plays an important role for the magnitude and evolution of mean stress. According to SEM fractography, the crack growth exhibits intergranular fracture under IP TMF and transgranular fracture under OP TMF. From the electron backscatter diffraction (EBSD) and transmission electron microscope (TEM) characterization results, the geometrically necessary dislocation (GND) density is higher for IP TMF, indicating more severe plastic deformation. The material shows cyclic softening in the high-temperature half-cycle, but cyclic hardening in the low-temperature half-cycle. The cyclic deformation is mainly related to dislocation activities under IP loading conditions, for which fatigue damage dominates the failure process. Under OP loading conditions, the deformation behavior is mainly associated with the generation of stacking faults (SF), and its failure mechanism includes both fatigue and oxidation damage.

Isothermal and thermo-mechanical fatigue-crack-growth analysis of XH73M nickel alloy

In service-power engineering and aviation, gas-turbine engine structures are operated at elevated temperatures and under extensive variable mechanical loading, which is classified as thermomechanical fatigue (TMF). This coupling effect leads to flaw initiation and growth in components fabricated from thermally resistant nickel-based alloys. This paper presents experimental crack-growth data for isothermal pure fatigue, in-phase and out-of-phase TMF conditions. A crack-growth testing method is developed using inductive heating/forced convective cooling and direct crack-tip opening displacement techniques. The crack-growth experimental results are interpreted based on finite element analyses of the stress–strain rate fields at the crack tip under TMF conditions. Therefore, multi-physics numerical calculations are employed for the interaction of the heat loss from magnetic-field eddy currents with forced convective air cooling through a computer fluid dynamics model, which presents a nonuniform mechanical elastic–plastic stress distribution. Consequently, the dependence of the new nonlinear stress intensity factors on the crack length are obtained for each of the isothermal and thermomechanical cyclic deformation conditions. The polycrystalline XH73M nickel-based alloy tests performed show that, from the crack-growth acceleration viewpoint, the following order of arrangement of fatigue fracture diagrams is formed: isothermal pure fatigue, in-phase TMF, out-of-phase TMF, and isothermal pure fatigue at T = 400 °C and T = 23 °C. The differences and corresponding conclusions based on the interpretation of the experimental results of the crack growth rate characteristics at elevated temperatures in terms of elastic and nonlinear fracture resistance parameters are discussed.

Molecular dynamics simulation of thermomechanical fatigue properties of Ni-based single crystal superalloys

In this paper, the thermomechanical fatigue (TMF) properties of Ni-based single crystal superalloys are studied by molecular dynamics simulations. Two different cyclic deformation mechanisms of superalloys are found under TMF loadings. The sample has a higher cyclic stress range, plastic strain energy density and a shorter fatigue life under Out-of-phase TMF loading than those under In-phase TMF loading. Moreover, the low-temperature tension half-cycle is more favorable for dislocations and stacking faults to cut into the γʹ precipitate phase, causing an earlier failure of superalloys under Out-of-phase TMF loading, which attracts more attention in actual operation.

Weft direction pseudo-thermomechanical fatigue behaviors of T300/ Polyimide-380 2.5D woven composites

This work elaborates the weft direction in-phase thermomechanical fatigue (IP TMF) behaviors of T300/PI-380 2.5D-WCs for the temperature variation between 100 and 300 °C for the first time. Results show that the IP TMF responses of 2.5D-WCs exhibit a low cycle fatigue characterization, which approximately linear decreases with the increase of cycle number. The hysteresis loops shifted to the right confirm an elongation of specimen during the IP TMF process. The residual stiffness and residual strength behaviors are also investigated in the case of TMF, and the corresponding numeric models are proposed based on the damage mechanics. Moreover, fracture morphologies of 2.5D-WCs under the IP TMF loading have been explored by means of SEM and X-rays observations. Finally, a probable failure mechanism for the weft direction IP TMF behaviors of 2.5D-WCs is proposed. This work provides a new benchmark in studying high-temperature fatigue properties of resin matrix 2.5D woven composites.

Thermomechanical fatigue and fracture behaviours of welded joints at various temperatures

Temperature variation plays a crucial role in the safe operation of welded structures during long-term high-temperature service. The present work aimed to explore the relationship between temperature variation and thermomechanical fatigue (TMF) fracture behaviours in welded joints. To achieve this target, isothermal fatigue (IF) and TMF tests were performed on P92 steel welded joint at different average temperatures (500 °C, 550 °C, 600 °C, 650 °C) and different temperature ranges (0 °C, 100 °C, 200 °C). Results showed that the increases in the average temperature and temperature range induce accelerated cyclic softening, reduction in fatigue life, and more evident dynamic strain ageing (DSA). However, there is an obvious difference in the cyclic response between IF, in-phase TMF and out-of-phase TMF. The decline of friction stress is responsible for the reduced peak stress at a higher average temperature. The back stress plays a more critical role in the cyclic stress response with increasing the temperature range. Moreover, the different diffusion rates of solute atoms and formation rates of carbides at various temperatures are responsible for the pronounced difference in DSA activity. Notably, the fracture location changes with the variation of temperature, which is directly correlated to the evolution of fatigue life. The competitive mechanism between fatigue damage and creep damage is responsible for the shift of fracture location.

In-phase thermomechanical fatigue studies on P92 steel with different hold time

Abstract The effect of hold time with 0, 20, and 40 s on in-phase thermomechanical fatigue (TMF) behavior and life of P92 steel is investigated in this study. TMF tests are carried out under mechanical strain control with strain amplitudes of 0.4 0.4 , 0.6 0.6 , and 0.8 % 0.8\text{\%} , and temperature range of 550–650°C which is closely relevant to the operating condition in power plant. TMF tests are performed in a mechanical strain ratio of R = − 1 R=-1 and cycle time of 120 s. The fatigue life variation follows the sequence of N f 0 s < N f 20 s < N f 40 s {N}_{\text{f}}^{0\hspace{.1em}\text{s}}\lt {N}_{\text{f}}^{20\hspace{.1em}\text{s}}\lt {N}_{\text{f}}^{40\hspace{.1em}\text{s}} for the same mechanical strain amplitude. In addition, the influence of hold time on fatigue life decreases with the increasing strain amplitude. A continuous softening can be observed from the cyclic stress response under all test conditions. Fractographic and microstructural tests indicate that the fracture surfaces are characterized by a multi-source cracking initiation and an oxidation phenomenon. Furthermore, a modified Ostergren model is used to predict the fatigue life and achieves a good predicted result.

Thermomechanical fatigue damage mechanism and life assessment of a single crystal Ni-based superalloy

The thermomechanical fatigue (TMF) of single-crystal air-cooled turbine blades is critical for accurately evaluating the lifetimes of advanced aero-engines. The present work focuses on the mechanical behavior and damage mechanism of a single-crystal Ni-based superalloy (DD6) under stress-controlled TMF loading, and in-phase (IP) and out-of-phase (OP) mode of TMF were conducted and compared with low cycle fatigue (LCF) loading. A ratcheting effect is observed during the deformation of DD6 under TMF loading, and the direction and size of the ratcheting strain are considerably influenced by the phase angle and mechanical load. The ratcheting strain increases with mechanical load and dwell time at high temperature, consequently shortening the lifetime of the material. The key factors affecting the TMF damage of DD6 are identified through a SEM analysis, which shows that the damage under IP TMF loading mainly comes from creep and fatigue, whereas that under OP TMF loading is dominated by oxidation and fatigue. Based on the critical plane approach, a fatigue life prediction model is proposed considering the ratcheting effect to predict the fatigue life of DD6 under TMF loading. The good agreement between the proposed model and experimental data indicates that the model has the potential to predict the fatigue life of DD6 under TMF loading.

A comparative study between in- and out-of-phase thermomechanical fatigue behaviour of a single-crystal superalloy

In this study, the difference between in-phase (IP) and out-of-phase (OP) thermomechanical fatigue (TMF) cycling at 100–850 °C of a single-crystal superalloy is investigated both from a mechanical response and resulting microstructure perspective. Results indicate that there is no significant difference in fatigue lives between IP and OP TMF when similar strain ranges and crystal orientations are considered. The deformation mechanisms occurring during IP and OP TMF are similar where the main deformation mechanism for this alloy is localized deformation bands and crack initiation is preferred to these bands. Other TMF mechanisms, such as recrystallization and oxidation, are also discussed.

Modelling the crack growth behaviour of a single crystal nickel base superalloy under TMF loading with long dwell times

The influence of hold time on the crack growth behaviour of a single crystal nickel base superalloy under in-phase thermomechanical fatigue is investigated. Two da/dt models were calibrated using creep crack growth tests in the temperature range 750–950 °C: one based on K and the other on (Ct)avg. The models were applied, in combination with a cycle dependent model, to predict da/dN of in-phase thermomechanical fatigue crack growth tests with 1–6 h hold time. The predictions based on K were inaccurate and generally non-conservative, whereas the predictions based on (Ct)avg were accurate. da/dt vs (Ct)avg followed a single trendline for all temperatures.

Cyclic plastic response and damage mechanisms in superaustenitic steel Sanicro 25 in high temperature cycling – Effect of tensile dwells and thermomechanical cycling

The cyclic plastic response and damage evolution in isothermal high temperature constant strain rate cycling and during in-phase thermomechanical fatigue in superaustenitic Sanicro 25 steel have been studied both with and without introduction of dwells at maximum strain. Fatigue hardening/softening curves and fatigue life curves are reported for all types of fatigue tests. Rapid hardening and a tendency to saturation has been found primarily in isothermal cycling with dwells and in thermomechanical cycling. Study of the surface damage evolution using SEM observations and FIB cutting revealed the preferential oxidation of grain boundaries perpendicular to the stress axis. Introduction of dwells in maximum tension leads to the enlargement of the plastic strain amplitude and to additional creep damage in the form of cavities along grain boundaries and internal cracks. Fatigue hardening rate in thermomechanical cycling is higher than in constant strain rate cycling and fatigue life decreases substantially in in-phase thermomechanical cycling. These findings are discussed in the perspective of effectiveness of dominant damage mechanisms relevant to individual types of cyclic straining.

Effect of constraint factor on the thermo-mechanical fatigue behavior of an Al-Si eutectic alloy

The thermo-mechanical fatigue (TMF) behaviors and corresponding damage mechanisms of Al-Si piston alloy were investigated in the temperature range of 120~425 °C under different constraint factors (η). The TMF hysteresis loops exhibit asymmetrical, because the yield strength and elastic modulus decrease significantly with the increasing temperature. Taking the phase angles into consideration, the mean tensile stress for out of phase TMF (OP-TMF, η<0) and mean compressive stress for in-phase TMF (IP-TMF, η>0) can be found. The fatigue life of IP-TMF is longer than that of OP-TMF except for higher constraint factor, and the life of TMF decreases with the increasing absolute value of η. There are two different crack initiation mechanisms under the constrain TMF: primary phases broken mainly for OP-TMF and matrix deboned mainly for IP-TMF. The oxidation may have only little influence on the crack behavior and TMF life, considering the obvious damage by deboned or broken primary phases. The tensile stress is key factor for fatigue crack initiation and growth in primary phases (Si and intermetallic) under cyclic deformation. The TMF life under different constrain factors can be predicted by the strain energy model with good precision.

Thermal-mechanical fatigue behaviour and life prediction of P92 steel, including average temperature and dwell effects

This study was devoted to an investigation of the effects of the average temperature and dwell on the thermal-mechanical fatigue (TMF) behaviour of P92 steel at elevated temperatures in the range of 350–650°C. The results revealed that increased average temperature decreased the in-phase TMF (IPTMF), out-of-phase TMF (OPTMF), and isothermal fatigue (IF) life values, and its effect was more significant in the range of 400–450°C. The effect of a short dwell time on the IPTMF life was dependent on the form of dwell, because tensile dwell decreased the IPTMF life and symmetric dwell increased the IPTMF life. Both creep stress relaxation (CSR) and dynamic strain ageing (DSA) were detected under IPTMF cycling. The application of dwell enhanced the CSR phenomenon. In contrast, the DSA effect was restrained, which was beneficial for fatigue resistance. The appearance of crack tip blunting and crack branching because of symmetric dwell indicated the retardation of crack propagation under the combined effects of enhanced CSR and the disappearance of the DSA phenomenon. In all cases, the transformation of lath structures into substructures was the dominant deformation mechanism. In addition, the equiaxial subgrain grew with increases in the strain amplitude and dwell time. Finally, the application of the current life models to P92 steel fatigue life prediction under both IF and TMF cycling were evaluated. Because of the insufficiency of the current models, a modified Coffin–Manson model is proposed by incorporating the mean stress and temperature into power law forms.

Isothermal and thermomechanical fatigue behaviour of type 316LN austenitic stainless steel base metal and weld joint

Thermomechanical fatigue (TMF) studies were carried out on type 316 LN austenitic stainless steel (SS) base metal (BM) and its weld joint (WJ) with a temperature interval of 623–873 K under in-phase (IP) and out-of-phase (OP) combinations of mechanical strain and temperature. Tests were performed under mechanical strain control mode using the strain amplitudes in the range, ±0.25% to ±0.6%. Besides, isothermal low cycle fatigue (IF) tests were also conducted on the weld joint at 873 K. TMF cycling resulted in a slightly higher cyclic stress response (CSR) compared to IF loading for the weld joint. The IP TMF cycling yielded a higher plastic strain amplitude in comparison to OP TMF for both the base metal and the weld joint. Cyclic life of the weld joint is found to be inferior to that of the base metal. The fatigue lives exhibited by the base metal and the weld joint varied in the following sequence: IP TMF < IF < OP TMF. Preferential crack initiation in the weld region owing to embrittlement of transformed δ-ferrite was noticed with an increase in the mechanical strain amplitude under both TMF and IF cycling conditions. Crack initiation and propagation generally occurred in transgranular mode under IF and OP TMF and mixed (trans-plus intergranular) mode under IP TMF cycling. Electron back scattered diffraction (EBSD) measurements were employed to investigate the substructural development in terms of local misorientation distribution, inverse pole figure (IPF) maps and boundary dislocation density (ρ) in the weld metal region, under IF and IP TMF cycling. The dislocation density was found to decrease for both IF and IP TMF cycling compared to the as-welded condition, with the decrease being higher for IF cycling. The TMF data generated for the type 316LN SS base metal and weld joint at different strain ranges in the present study clearly demonstrated a lack of conservatism associated with the current design practice which is based on the IF data at the maximum temperature (Tmax) of the service cycle.