Thermomechanical Fatigue Tests Research Articles

Thermomechanical and isothermal fatigue properties of MAR-M247 superalloy

Thermomechanical low-cycle fatigue (TMF) tests were performed on polycrystalline cast nickel-based superalloy MAR-M247 under in-phase (IP) and out-of phase (OP) loading in the temperature range of 500–900 °C. A constant heating and cooling rate of 5 °C.s−1 was selected. Furthermore, isothermal low-cycle fatigue (ILCF) tests with the same cycle period as TMF cycle were carried out at the maximal temperature of TMF cycle (900 °C). All tests ran under strain control and fully reversed cycle on solid cylindrical specimens in laboratory air. High resolution scanning electron microscopy and transmission electron microscopy were utilized to characterize the damage mechanism occurring during TMF and ILCF loading. The cyclic deformation and lifetime behaviour as well as damage mechanisms dependent on loading regime were examined. Results show that the TMF loading has a detrimental effect on the lifetime of MAR-M247. Lifetime reduction is most significant under IP loading. The fracture surfaces are characterized by typical striation fields, where the largest spacing between striations was observed for IP loading with prevailing intercrystalline cracking followed by OP and isothermal ILCF loading with transcrystalline crack propagation. To improve discussion of obtained results, experimental data were compared with damage and life prediction models.

Constitutive model of an additively manufactured combustor material at high-temperature load conditions

ABSTRACT In this paper, the high-temperature constitutive behaviour of an additively manufactured ductile nickel-based superalloy is investigated and modelled, with application to thermomechanical fatigue, low-cycle fatigue and creep conditions at temperatures up to 800 ∘ C. Thermomechanical fatigue tests have been performed on smooth specimens in both in-phase and out-of-phase conditions at a temperature range of 100 − 800 ∘ C, and creep tests at 625 ∘ C, 700 ∘ C, 750 ∘ C and 800 ∘ C. Additionally, low-cycle fatigue tests at different strain ranges and load ratios have been performed at 700 ∘ C, and tensile tests have been performed at 600 ∘ C, 700 ∘ C and 800 ∘ C. A clear anisotropic mechanical response is obtained in the experiments, where the anisotropic effects are larger at high stress levels in creep loadings. To capture this behaviour, a rate-dependent strain based on a double-Norton model has been adopted in the model, by which the creep and mid-life response of the thermomechanical fatigue tests can be simulated with good accuracy.

Thermo-mechanical fatigue behavior and microstructure evolution of 4Cr5Mo3V hot work die steel

Thermo-mechanical fatigue (TMF) testing was used to study the fatigue behavior of 4Cr5Mo3V hot work die steel to reflect the in-service conditions. The synergistic effect of cyclic temperature and mechanical load was investigated using a strain-controlled method. Our results confirmed that the cyclic softening degree of 4Cr5Mo3V steel increased as the mechanical strain amplitude get bigger, leading to a reduction of the fatigue life. The microstructure evolution was studied before and after the TMF testing, and it was found the maximum texture strength in as-received steel decreased from 7.22 to 2.34 when the strain amplitudes was set as ± 1.1 %. Experimental evidence showed that martensite decomposition, oxidation, dislocation density reduction and carbide segregation all contributed to the final TMF failure. Severe deformation existed in the vicinity of the newly precipitated M2C carbide during the TMF process, acting as fatigue crack initiation sources due to stress concentration. Four different models were interrogated including Basquin-Coffin-Manson model, Smith-Watson-Topper (SWT) model, Ostergren model and 3SE energy model; and it was found that SWT model yielded the best fatigue life description. Nevertheless, all the four models showed reasonable fitting capability within the 2x scatter band, which proved the reliability of the experiments established in this study.

Insights into thermomechanical fatigue behavior of nitrogen alloyed 316LN stainless steel under various temperature cycling ranges

Thermomechanical fatigue (TMF) failure has become one of the most important life-limiting factors of components exposure to the high temperature in the fourth-generation sodium-cooled fast reactor (SFR) nuclear power plant. Therefore, TMF tests at different temperature cycling ranges are performed to study the cyclic deformation behavior and damage mechanism of a nitrogen alloyed 316LN stainless steel. Moreover, the isothermal fatigue (IF) tests at the maximum temperature of TMF cycling are conducted for comparison. The cyclic hardening and softening response are analyzed, taking into account the phenomenon of dynamic strain aging which occurs at the temperature range of 350 °C–650 °C. Furthermore, the critical strain corresponding to the occurrence of serrated stress flow in engineering stress-strain curves keeps decreasing from 28.94% at 350 °C to 0.09% at 650 °C. The distribution of plastic deformation and the degree of strain localization are evaluated by the characterization results of kernel average misorientation map, high/low angle grain boundary map and dislocation configuration. The dominant damage mechanism and its corresponding cracking behavior in both IF and TMF tests are analyzed based on the observation of fracture surface morphology. In addition, the sequence order of fatigue life is determined as IF < IP-TMF < OP-TMF. Moreover, the maximum difference of fatigue life between IF test and TMF test occurs at the temperature range of 400 °C–600 °C, in which the IP and OP life is about 2.91 and 3.65 times larger than the IF life. The results in this work provide reliable data support and theoretical guidance for the fatigue design of high-temperature components in SFR.

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.

Thermomechanical fatigue behavior and failure mechanism of a nickel-based directional solidification column crystal superalloy

Thermomechanical fatigue (TMF) is a primary cause of turbine blade failure. TMF tests of a nickel-based directional solidification superalloy, which is a typically used material for turbine blades, are performed out in the surface temperature range of 400 °C–700 °C, two phases (in-phase and out-of-phase, i.e. IP and OP, respectively), three stresses, and two stress ratios. The test results idicate that the TMF life of the OP exceeds that of the IP. An increase in the stress ratio prolongs the TMF life. Scanning electron microscopy and transmission electron microscopy are performed to investigate the failure mechanism. The TMF failure behavior is complex and mainly includes fatigue, creep, and oxidation damage, with a quasi-cleavage fracture mode. Based on the theory of crystal plasticity as well as comprehensively considering the failure mechanism and focusing on the statistical characteristics of the thermal–stress interaction, a TMF constitutive model is established, which explains the differences in TMF behavior between the IP and OP conditions from a theoretical perspective.

Verification and validation of multi-physics numerical analysis of thermomechanical fatigue test conditions under induction heating and forced convection

This paper presents the validation and verification of thermomechanical fatigue multi-physics numerical analysis. To determine the local thermomechanical stress–strain state and displacement fields, an algorithm for the multi-physics numerical calculations is developed and implemented incorporating the Maxwell 3D, Fluent, and Transient Structural modules of ANSYS 2021R1. Single-edge-notch tension specimen heating is modelled using a rectangular induction coil. The temperature distribution in the specimen under forced and natural convection is considered. The nonlinear solid mechanics are analysed considering the temperature nonuniformity under in-phase and out-of-phase loading cycles with a triangular waveform and temperature range of 400–650 °C. Sensitivity analysis is performed to explore the effects of the mesh density. To complement the multi-physics computations, crack-opening displacement and infrared thermography temperature distribution measurements are employed for the thermomechanical fatigue test control in a single-edge-notch tension specimen produced from a nickel-based alloy XH73M. Based on the interconnected verification and validation of coupled numerical analysis, recommended ranges of numerical model parameters have been found to provide a stable solution.

Isothermal and thermomechanical fatigue behavior of Ti-2Al-2.5Zr titanium alloy

In-phase and out-of-phase thermomechanical fatigue (TMF) tests in the temperature range of 200–400 °C and isothermal fatigue (IF) tests at 400 °C were conducted to investigate cyclic deformation behavior and fatigue life of Ti-2Al-2.5Zr alloy. The back stress and the friction stress were extracted, and the internal stress competition mechanism underlying the cyclic hardening/softening behavior was clarified. The fatigue life of TMF and IF exhibited slight differences at strain amplitudes greater than 0.6%, whereas it depended on loading modes at the strain amplitude of 0.4% owing to the increase in the relative deviation in the plastic strain energy density and in the peak stress.

Can Martensitic Phase Transformation Measured by Magnetic Methods be an Indicator of Fatigue Damage in Austenitic Steel at Elevated Temperature and Thermo-Mechanical Loading?

The phenomenon of phase transformation from paramagnetic γ austenite to ferromagnetic α' martensite in metastable austenitic stainless steels under fatigue loading is well investigated, especially at ambient temperature. Generally, it can be said that at ambient temperature, the amount of martensite is proportional to the accumulated plastic strain and, therefore, can be an early indicator of fatigue damage. The problem arises at elevated temperatures when the thermal energy can severely or even completely inhibit the phase transformation. In this case, the amount of α'-martensite can no longer be a good indicator of fatigue damage. The question is, where is the limit the deformation-induced martensite can still be used as a fatigue damage indicator? To answer this question, several fatigue tests have been performed on AISI 347 (X6CrNiNb18-10), a metastable austenitic stainless steel often used in the piping of European nuclear powerplants. Tests included isothermal fatigue tests as well as thermo-mechanical fatigue (TMF) loading in the range of 25 to 320 °C. Deformation-induced martensite was measured in situ by means of a uniaxial magnetic balance, from which the rate of phase transformation was obtained. Fatigue specimens were then cut to investigate the distribution of martensite in the gauge length by means of magnetic force imaging. The results showed that isothermal fatigue loading results in a steady decrease in phase transformation rate with temperature. Initial martensite nucleation was observed to be different at elevated temperatures and occurred only at the surface, where sufficient shear deformation was present. TMF tests showed higher than isothermal rates of phase transformation. Peak temperatures above 300 °C were nevertheless enough to severely reduce the formation of α' martensite, even when cooled back to ambient temperature in the other half of the TMF cycle.

Elastic modulus data for additively and conventionally manufactured variants of Ti-6Al-4V, IN718 and AISI 316 L

This article reports temperature-dependent elastic properties (Young’s modulus, shear modulus) of three alloys measured by the dynamic resonance method. The alloys Ti-6Al-4V, Inconel IN718, and AISI 316 L were each investigated in a variant produced by an additive manufacturing processing route and by a conventional manufacturing processing route. The datasets include information on processing routes and parameters, heat treatments, grain size, specimen dimensions, and weight, as well as Young’s and shear modulus along with their measurement uncertainty. The process routes and methods are described in detail. The datasets were generated in an accredited testing lab, audited as BAM reference data, and are hosted in the open data repository Zenodo. Possible data usages include the verification of the correctness of the test setup via Young’s modulus comparison in low-cycle fatigue (LCF) or thermo-mechanical fatigue (TMF) testing campaigns, the design auf VHCF specimens and the use as input data for simulation purposes.

Impacts of nano-clay particles and heat-treating on out-of-phase thermo-mechanical fatigue characteristics in piston aluminum-silicon alloys

Abstract. In this article, the effect of nano-clay particles and heat-treating on thermo-mechanical fatigue (TMF) behaviors and failures of piston aluminum-silicon (AlSi) alloys was investigated. For this purpose, thermo-mechanical fatigue tests were conducted under out-of-phase (OP) loading conditions. Two loading conditions were checked based on different maximum temperatures (250, 300, and 350 °C) and various thermo-mechanical loading factors (100, 125, and 150%). The minimum temperature was constant in all tests at 50 °C under a heating/cooling rate of 10 °C/s and a dwell time of 5 s. Results showed that the nano-composites had a longer fatigue lifetime, at least 2 times higher, compared to the Al alloy, when the maximum temperature was 250 °C and the thermo-mechanical loading factor was 100%. However, no effective change was seen for the stress value and the plastic strain. At higher maximum temperatures, the change in the material behavior was lower. The fracture analysis by scanning electron microscopy (SEM) demonstrated that both materials had a brittle behavior due to cleavage and quasi-cleavage marks. The damage mechanism was also due to the Si-rich phase and intermetallics, respectively for the crack propagation and the micro-crack initiation.

Creep–Fatigue Interaction of Inconel 718 Manufactured by Electron Beam Melting

Electron beam melting of Ni‐base superalloy Inconel 718 allows producing a columnar‐grained microstructure with a pronounced texture, which offers exceptional resistance against high‐temperature loading with severe creep–fatigue interaction arising in components of aircraft jet engines. This study considers the deformation, damage, and lifetime behavior of electron‐beam‐melted Inconel 718 under in‐phase thermomechanical fatigue loading with varying amounts of creep–fatigue interaction. Strain‐controlled thermomechanical fatigue tests with equal‐ramp cycles, slow–fast cycles, and dwell time cycles are conducted in the temperature range from 300 to 650 °C. Results show that both dwell time and slow–fast cycles promote intergranular cracking, gradual tensile stress relaxation, as well as precipitate dissolution and coarsening giving rise to cyclic softening. The interplay of these mechanisms leads to increased lifetimes in both dwell time and slow–fast tests compared to equal ramp tests at higher strain amplitudes. Conversely, at lower mechanical strain amplitudes, the opposite is observed. A comparison with results of conventional Inconel 718 indicates that the electron‐beam‐melted material exhibits superior resistance against strain‐controlled loading at elevated temperatures such as thermomechanical fatigue.

Isothermal low-cycle fatigue, fatigue–creep and thermo-mechanical fatigue of SiMo 4.06 cast iron: Damage mechanisms and life prediction

A series of strain-controlled Low-Cycle Fatigue tests (LCF) and Thermo-Mechanical Fatigue tests (TMF) were performed on silicon-molybdenum ductile cast iron SiMo 4.06. LCF tests were performed for various mechanical strain amplitudes at a high strain rate of 3×10−3/s for various temperatures between 20 °C and 750 °C. In addition, several LCF tests were performed for a low strain rate of 1×10−4/s and as fatigue–creep tests with a tensile strain dwell. TMF tests were performed as out-of-phase and fully constrained between 100 °C and 650 °C. The investigation of the damage mechanisms revealed that the predominant failure mode is a combination of graphite-matrix debonding and transgranular crack propagation through ferritic matrix. Finally, a novel damage model based on the dissipated hysteresis energy is proposed in order to effectively predict the lifetime of SiMo 4.06 under LCF and TMF loading. Creep and fatigue damage are each calculated separately and the oxidation effect is taken into account indirectly.

Thermomechanical fatigue of Nickel-Based Single-Crystal superalloys

Nickel-based single-crystal superalloys are extensively used in aeroengine hot-end components owing to their unique crystal structure and outstanding high-temperature mechanical properties. In this study, a thermomechanical fatigue (TMF) test platform capable of realizing precise temperature control and coordinated control of mechanical and temperature loads was constructed. The TMF of a second-generation nickel-based single-crystal superalloy (DD6) was analyzed in a temperature range of 500–950 °C at a stress ratio of 0.1 in two phases (in-phase and out-of-phase); moreover, the TMF tests were conducted at various stress levels, and the TMF life of the single-crystal specimens was determined. The OP TMF lifetime was considerably longer than the IP TMF lifetime at identical stress levels. The failure mechanism of the material in different phases was elucidated. The fracture and microstructures of the specimens were analyzed by SEM and TEM. For the IP specimens, the fracture mode was determined to be a quasi-cleavage fracture, and the γ' phase exhibited N-type rafting prior to fracture. For the OP specimens, the fracture was relatively smooth and flat. Numerous fine secondary γ' phases are precipitated in the channels of the matrix phase.

Life prediction method based on damage mechanism for titanium alloy TC4 under multiaxial thermo-mechanical fatigue loading

In this paper, a life prediction method based on damage mechanism for titanium alloy TC4 under multiaxial thermo-mechanical fatigue loading is proposed. Temperature and time dependent influence factors are proposed and introduced into the strain amplitude-life curve method to consider the temperature and time dependence of damage, respectively. The increase in fatigue and oxidation damages caused by tensile mean stress and non-proportional additional hardening is expressed by the mean stress in Macaulay brackets and by using a multiaxial damage parameter, respectively. A fast cracking influence factor is proposed to consider the influence of fast cracking of materials caused by the combined action of high temperature, tensile stress and shear stress on damage behavior. The material constants are identified by test data under uniaxial and proportional loadings, and are further used for prediction under non-proportional loading. The failure life results of uniaxial isothermal fatigue tests with and without dwell time, uniaxial and multiaxial thermo-mechanical fatigue tests are used to verify the proposed method. The value of the scatter band of life prediction result is less than ± 2, as well as the maximum and mean relative errors between predicted and experimental strain amplitudes are 18.49% and 6.54%, respectively.

Strengthening mechanism in thermomechanical fatigue properties of Ti6Al4V titanium alloy by laser shock peening

In this study, the role of laser shock peening (LSP) on the thermomechanical fatigue properties of Ti6Al4V titanium alloy was investigated. The effects of LSP with different coverage layers on the microstructural evolution, residual stresses distribution, and thermomechanical fatigue lives were systematically analyzed by scanning electron microscopy, transmission electron microscope, residual stresses tests, microhardness tests, and thermomechanical fatigue tests. Results showed that the thermomechanical fatigue lives of the LSP1 and LSP2 specimens at room temperature increased by 48.00 % and 114.95 %, respectively. While the fatigue life of the LSP2 specimen increased by 68.91 % even under high-temperature heat cycle. Meanwhile, the locations of crack initiations in the LSPed specimens were significantly shifted to the sub-surface with a smaller fatigue initiation region area compared to the unLSPed specimen. Furthermore, the fracture surface was essentially occupied by equiaxed dimples and small-spaced fatigue striations. LSP-induced considerable depth of severe plastic deformation in the near-surface of Ti6Al4V titanium alloy, generating gradient compressive residual stresses, high-density dislocation structures (dislocation lines, dislocation tangles, dislocation walls, and dislocation cells), and grain refinement (nanograins and nanotwins). These three main factors contributed to inhibiting the sprouting and propagation of cracks during the thermomechanical fatigue tests and played a primary role in improving the thermomechanical fatigue properties.

A comparison on isothermal and thermomechanical fatigue behavior of 316LN stainless steel with various tension dwell time

Isothermal and thermomechanical fatigue tests with various tension dwell time (designated as creep-IF and creep-TMF respectively) were conducted. The cyclic stress response and stress relaxation behavior were qualitatively and quantitatively discussed based on TEM and EBSD characterization. The fatigue dominated transgranular crack initiation and propagation led to specimen fracture in all creep-IF tests. The transition of dominant damage mechanism from fatigue to creep-fatigue interaction occurred when dwell time increased to 1800 s in creep-TMF test, which caused the intergranular fracture mode and a much shorter life than creep-IF. Moreover, the life prediction model based on tension strain energy was proposed.

Laves Phase Precipitation Behavior in HiperFer (High Performance Ferritic) Steel with and without Boron Alloying

High-chromium ferritic stainless HiperFer steels were developed for high-temperature applications in power conversion equipment. The presented research describes the precipitation behavior of the Laves phase after the thermomechanical treatment of Fe-17Cr-0.6Nb-2.4W HiperFer alloys with and without the addition of 55 ppm boron. The boron-alloyed variant was produced with the aim of enhancing grain boundary strengthening and consequently increasing creep resistance. The focus is set on the effect of boron on the thermomechanically induced precipitation of (Fe,Cr,Si)2(Nb,W) Laves phase at grain boundaries. The addition of boron modifies the diffusion conditions in the area of grain boundaries. Consequently, the formation of Laves phase is promoted and the particle growth and coarsening process are suppressed. The impact of boron addition was validated by performing creep and thermomechanical fatigue testing in the standard processing state of HiperFer steel. In the B-alloyed variant, increased creep ductility through the modification of the particle-free zone widths at high-angle grain boundaries was encountered. Nevertheless, an optimized thermomechanical treatment is necessary to fully utilize the increased ductility effect for the creep strength optimization of the B-alloyed grade.

A Temperature-Dependent Viscoplasticity Model for the Hot Work Steel X38CrMoV5-3, Including Thermal and Cyclic Softening under Thermomechanical Fatigue Loading.

In this paper, a temperature-dependent viscoplasticity model is presented that describes thermal and cyclic softening of the hot work steel X38CrMoV5-3 under thermomechanical fatigue loading. The model describes the softening state of the material by evolution equations, the material properties of which can be determined on the basis of a defined experimental program. A kinetic model is employed to capture the effect of coarsening carbides and a new isotropic cyclic softening model is developed that takes history effects during thermomechanical loadings into account. The temperature-dependent material properties of the viscoplasticity model are determined on the basis of experimental data measured in isothermal and thermomechanical fatigue tests for the material X38CrMoV5-3 in the temperature range between 20 and 650 ∘C. The comparison of the model and an existing model for isotropic softening shows an improved description of the softening behavior under thermomechanical fatigue loading. A good overall description of the experimental data is possible with the presented viscoplasticity model, so that it is suited for the assessment of operating loads of hot forging tools.

Thermo-Mechanical Fatigue Behavior and Resultant Microstructure Evolution in Al-Si 319 and 356 Cast Alloys.

The out-of-phase thermo-mechanical fatigue (TMF) behavior of the two Al-Si cast alloys most widely used for engine applications (319 and 356) were investigated under temperature cycling (60-300 °C) and various strain amplitudes (0.1-0.6%). The relationship between the microstructural evolution and TMF behavior was closely studied. Both alloys exhibited asymmetric hysteresis loops with a higher portion in the tensile mode during TMF cycling. The two alloys showed cyclic softening behavior with regard to the maximum stress, but an earlier inflection of cyclic stress was found in the 356 alloy. The TMF lifetime of the 319 alloy was generally longer than that of the 356 alloy, especially at higher strain amplitudes. All the precipitates (β'-MgSi in 356 and θ'-Al2Cu in 319) coarsened during the TMF tests; however, the coarsening rate per cycle in the 356 alloy was significantly higher than that in the 319 alloy. An energy-based model was applied to predict the fatigue lifetime, which corresponded well with the experimental data. However, the parameters in the model varied with the alloys, and the 356 alloy exhibited a lower fatigue damage capacity and a higher fatigue damage exponent.