Transgranular Cracking Research Articles

Thermo-mechanical fatigue behavior and life prediction of selective laser melted inconel 718

The thermo-mechanical fatigue (TMF) property and corresponding damage mechanisms of selective laser melted (SLM) Inconel 718 superalloy were investigated systemically. The results show that the TMF life under in-phase (IP) loading is lower than that under out-of-phase (OP) loading, and the life difference gradually decreases with decreasing the strain amplitude. The fatigue cracks mainly exhibit inter-granular cracking characteristics under IP loading, and the δ phase embedded to the grain boundary promotes the creep cavity formation and then causes the fatigue crack propagation. While under OP loading, the fatigue crack is mainly characterized by trans-granular cracking, the oxidation induced crack extends from the specimen surface to the interior. A parameter, known as the shape factor k, has been discovered to exhibit high stability in temperature variations. Given the high stability of the k value and the quantitative relationship between stress and plastic strain range across different loading modes, a rapid prediction method for TMF hysteretic energy based on low cycle fatigue (LCF) has been proposed. Finally, combined with the energy cumulative damage model, the TMF life is successfully predicted. This approach significantly reduces the experimental quantity and complexity required for the TMF life prediction process, demonstrating substantial industrial application value.

Effect of grain size and grain boundary type on intergranular stress corrosion cracking of austenitic stainless steel: A phase-field study

A phase-field model coupled with polycrystalline microstructure is utilized to investigate the effect of grain size and grain boundary types on intergranular stress corrosion cracking in austenitic stainless steels. Considering the dilute solution environment, the free energy density of the two phases is hypothesized to be in parabolic form. The slower corrosion crack propagation rate in coarse-grained microstructures can be attributed to a higher frequency of transgranular cracking. Low-angle grain boundaries can effectively deflect intergranular corrosion cracks into grains with lower corrosion susceptibility, thereby impeding crack propagation. Twin boundaries mitigate corrosion crack propagation by reducing potential initiation sites.

Creep-fatigue interactive behavior and damage mechanism of TP321 stainless steel under hybrid-controlled conditions

In this study, Hybrid-controlled creep-fatigue (HCCF) tests were conducted on TP321 austenitic stainless steel under a variety of test conditions. The effects of strain amplitude, holding time, holding stress and temperature on the creep-fatigue behavior of TP321 austenitic stainless steel were not only analyzed in detail but also revealed the creep-fatigue damage interactive mechanism. The results demonstrated that a rise in test temperature and load holding time markedly induced creep deformation, resulting in a notable reduction in failure life. Additionally, an increase in test temperature led to the cessation of the cyclic hardening phenomenon. Secondly, the analysis of fracture morphology and X-ray computed tomography (X-CT) scanning results demonstrated that the transgranular cracks expanded inwards and connected with the intergranular voids under creep-fatigue interaction, forming a mixed intergranular and transcrystalline fracture mode. The presence of large creep cavities impeded the propagation of fatigue cracks when creep damage was the dominant phenomenon. Subsequently, the damage evolution mechanism was elucidated through microstructural analysis, which revealed that the impact of the slip bands on the triangular grain boundaries and the precipitation of carbides facilitated the nucleation of voids and the internal formation of intergranular microcracks, thereby causing creep-fatigue damage interaction. Finally, the TP321 austenitic stainless steel creep-fatigue damage interactive mechanism diagram was proposed in conjunction with the fracture morphological characteristics and microstructure.

Microstructures, phase and mechanical characterisation of Al2O3-ZrO2-TiO2 coating produced by atmospheric plasma spraying

The microstructure, crystallographic phases, and mechanical properties of a newly developed Al2O3 – TiO2 – ZrO2 ternary ceramic coating were characterized. The coatings were produced by atmospheric plasma spraying as a preblended powder on Ti-6Al-4 V substrates using the new generation of the Debye-Larmor cascaded plasma torch. The 400 μm thick as-sprayed ternary ceramic coating is compact and neither delamination nor inter-/trans-granular cracks were found. The coating consists of single phase α-Al2O3, monoclinic m-ZrO2, and a nanocrystalline dual phase structure of α-Al2O3 and m-ZrO2. Ti is either present as ZrTiO4 or as solute in the dual phase. Cracking from the tip of the indent is rare and delamination was not observed after the progressive scratch test. The coating has potential in high wear applications for example in medical devices.

Ordering-facilitated lower hydrogen embrittlement sensitivity in a prototype high-entropy alloy

The ageing treatment (450 °C/60 h) led to the spinodal decomposition at grain boundaries (GBs) and the development of chemical short-range orders (CSROs) in the alloy matrix, increasing the strength and effectively reducing the HE sensitivity of the equiatomic FeMnNiCoCr alloy. Firstly, the emergence of NiMn- and Cr-rich orders at GB regions reduces hydrogen diffusion rates along GBs and limits hydrogen enrichment at these sites. Secondly, CSROs promote hydrogen accumulation within the grain interior and impede hydrogen penetration, resulting in a shallower hydrogen-affected depth in the aged sample. Moreover, the modulation of hydrogen distribution by microstructure initiates transgranular cracking in the aged sample.

Insights from tensile fracture properties and full-field strain evolution of deep coral reef limestone under dynamic loads

Coral reef limestone (CRL) commonly undergoes dynamic tension when underground structures of island reefs encounter impacts, explosions, or seismic activities. Given the complexity of biological pores, the dynamic tensile fracture characteristics of CRL are poorly understood. Therefore, the dynamic tensile fracture behaviors of deep CRL were systematically observed by Split Hopkinson Pressure Bar tests and digital image techniques. Comparing to traditional rocks, the macro-pores near failure band would significantly change cracking path. The failure patterns are dominated by loading rate. The strongly dependence of dynamic tensile strength and dynamic crack initiation toughness on loading rate suggests the two indices overcome the effect of CRL macro-pores under dynamic impacts. At low loading rates, tensile fractures predominantly follow intergranular cracks, whereas transgranular cracks dominate at higher rates. The fractal dimension of fracture surface decreases with increasing crack propagation velocity, loading rate, and dynamic crack initiation toughness. Due to the unique marine sedimentary environment, the mechanical heterogeneity in multiple scales distinguishes CRL from terrestrial rock materials. The insights into underlying mechanisms of dynamic tension provide support to optimization of blasting scheme and stability assessments for island underground engineering.

Fatigue crack growth rate under mixed-mode loading conditions (I+III) of a carbide-free bainitic steel designed for rail applications

Carbide-free bainitic steel was designed for railway infrastructure application, focusing on high-speed and heavy-loaded freight tracks. Considering the complex state of stresses occurring on the rails running surface, mode III plays a significant role in the initiation and propagation of fatigue cracks of rails during service. Thus, the Fatigue Crack Growth Rate (FCGR) under mixed-mode loading conditions (I+III) was evaluated. It was revealed, that fatigue lifetime increases with loading angle modes. In the area of fatigue fracture, transgranular cracking mechanisms dominated. For the stable fatigue crack growth, a trend was observed related to the decrease in the fraction of intergranular fracture with the increasing loading angle modes (α). Secondary cracks indicated privileged cracking directions related to the crystallographic structure of bainite. The influence of the mechanical stability of retained austenite during mixed-mode FCGR requires further in-depth research. These studies contribute to understanding the factors influencing the reliability of railway tracks in terms of designing new materials and modeling the rate of crack growth to precise assessment of the life cycle of rails.

Microstructure, deformation and fracture mechanism of Mg-Gd-Y-Zn-Zr alloy with different rolling routes during tension

The microstructure, deformation and fracture mechanism of unidirectional rolling (UR) and cross rolling (CR) Mg-4.7Gd-3.4Y-1.2Zn-0.5Zr alloy during tension were studied. Both rolled alloys exhibit typical bimodal microstructures, with the difference being that UR alloy has elongated grains containing rod LPSO phase, while CR alloy has relatively rounded deformed grains containing lamellar LPSO phase. After tension until fracture, the LPSO phase morphology of the two alloys remains unchanged. CR alloy exhibits a higher yield strength and lower elongation than UR alloy. Although the higher average basal <a> slip Schmid factor result in the lower yield strength of UR alloy, the activation of the high proportion of non-basal slip is responsible for its higher elongation. UR alloy and CR alloy exhibit ductile fracture and quasi cleavage fracture characteristics, respectively. For UR alloy, a variety of dislocations accumulated near grain boundary and the weak slip transfer effects between grains both contributes to the propagation of grain boundary cracks. However, the effects of weak interfacial bonding between metastable lamellar LPSO phase and matrix, along with the similar orientation and higher geometric compatibility of CR alloy, lead to the rapid spread of transgranular cracks.

Using physics-informed neural networks to predict the lifetime of laser powder bed fusion processed 316L stainless steel under multiaxial low-cycle fatigue loading

Axial-torsional Low-Cycle Fatigue (LCF) tests were conducted under strain control on Additively Manufactured (AM) 316L stainless steel using laser powder bed fusion. The tests covered various strain amplitudes under tension-compression, proportional, and pure shear loading paths. The AM 316L stainless steel exhibited cyclic softening and transgranular cracking under all the investigated loading conditions. The presence of deposition defects, predominantly the lack of fusion type, was identified as the main factor influencing the crack initiation and propagation, as well as the scatter in the fatigue lifetime. Therefore, to account for the damaging effects of these deposition related defects on fatigue lifetime, a novel physics-informed neural network was proposed. Subsequently, this neural network was combined with the critical plane approach, based on the tensile mode of failure, in order to predict the lifetime of AM 316L stainless steel. The predicted data exhibited a good correlation with the experimental results.

A thermodynamic framework for ductile phase-field fracture and gradient-enhanced crystal plasticity

This study addresses ductile fracture of single grains in metals by modeling of the formation and propagation of transgranular cracks. A proposed model integrates gradient-extended hardening, phase-field modeling for fracture, and crystal plasticity. It is presented in a thermodynamical framework in large deformation kinematics and accounts for damage irreversibility. A micromorphic approach for variationally and thermodynamically consistent damage irreversibility is adopted. The main objective of this work is to analyze the capability of the proposed model to describe transgranular crack propagation. Further, the micromorphic approach for damage irreversibility is evaluated in the context of the presented ductile phase-field model. This is done by analyzing the impact of gradient-enhanced hardening considering micro-free and micro-hard boundary conditions, studying the effect of the micromorphic regularization parameter, evaluating the performance of the model in ratcheting loading and testing its capability to predict three-dimensional crack propagation. In order to solve the fully coupled global and local equation systems, a staggered solution scheme that extends to the local level is presented.

Creep-fatigue damage level evaluation based on the relationship between microstructural evolution and mechanical property degradation

Creep-fatigue interaction is identified as a primary failure mode for components operating under high temperatures. As operational durations extend, this interaction not only alters the material's microstructures but also initiates a gradual degradation in mechanical properties, significantly impacting its deformation and damage behaviors. In this work, the dynamic microstructural evolution of GH4169 superalloy during creep-fatigue was elucidated via qualitative characterization, and damage level evaluation method was subsequently developed by bridging microstructure degradation to mechanical property degradation. Creep-fatigue tests were performed at 650 °C with various tensile holding times and were interrupted at lifetime fractions of 10 %, 50 % and 80 % for further analysis and tensile evaluations. Results revealed that the prolonged exposure to holding times induced the coarsening of γ″ precipitates alongside an increase in low-angle grain boundaries, culminating a reduction in creep-fatigue strength. The development of voids and cracks exacerbated the degradation of elongation, leading to a hybrid fracture mode encompassing both intergranular and transgranular cracking paths. Synthesizing microstructural evolutions to qualitatively categorize diverse degradation levels imparted a robust physical basis for damage evaluation. A mapping model was established to correlate the average kernel average misorientation (micro-degradation indicator) with the tensile plastic strain energy density (macro-degradation indicator). The damage level evaluation method was endowed with quantitative metrics utilizing this model, and its generality was additionally validated in P92 steel. This work offers an insight into the quantitative damage evaluations of creep-fatigue-induced degradations in materials, thereby providing a theoretical basis for the development of operation management and inspection plans of components.

Unraveling the plastic deformation, recrystallization, and oxidation behavior of Waspaloy during thermal fatigue crack propagation

Thermal fatigue is one typical failure mode for engine components involving cyclic thermal stresses/strains. However, the microstructure evolution and its microscopic interaction with thermal fatigue cracking in Ni-based superalloys featuring intragranular γ′ and intergranular carbides have yet to be clarified. In this study, cyclic temperature variations ranging from 25 °C to 700 °C were conducted on Waspaloy to unravel the synergistic damage mechanisms including stress distribution, plastic deformation, recrystallization, oxidation, and crack propagation. The thermal fatigue cracks are found to predominantly propagate along grain boundaries with a gradually descending rate from 3.5 μm/cycle to 1.5 μm/cycle. Compared with the macroscopic thermal stress up to ∼800 MPa, the local thermal stress induced by different sizes of M23C6 carbides marginally affects the crack propagation. Intensive slip bands and sparse deformation twins in the deformed matrix are observed, indicating the plastic deformation is mainly achieved by dislocation slipping and supplemented by twinning. Trans-granular cracks parallel to {111} planes form occasionally when the propagation directions of intergranular cracks are almost parallel to the {111} slip bands. Besides, dislocations promote the oxidation damage of the crack surface through pipe diffusion of solutes, and the γ′-precipitate free zones (PFZs) and recrystallized areas are produced accordingly. The quantitation analysis of the PFZ thickness provides a reference for predicting crack initiation time during thermal fatigue.

Stress Corrosion Cracking of 304 Austenitic Stainless Steel in H2SO4/NaCl Media at Room Temperature

The effects of Cl− ion concentration, H2SO4 concentration, the applied potential, and the strain rate on the stress corrosion cracking (SCC) of 304 stainless steel were investigated. The postfracture scanning electron microscope micrographs of the fractured surfaces revealed that solutions of high H2SO4 concentration combined with low Cl− ion concentration resulted in corrosion (active dissolution), while solutions of very low H2SO4 concentration combined with a relatively moderate Cl− ion concentration resulted in ductile failure. Solutions with moderate concentrations of H2SO4 and Cl− ions resulted in transgranular SCC. The susceptibility to SCC and the fracture surface morphology were found to depend on the [H2SO4]/[Cl−] ratio, the strain rate, and the applied potential. The average crack-growth rate (ACGR) was found to depend on the strain rate and the applied potential. For specimens undergoing SCC at the open-circuit potential, the ACGR increased with increasing the strain rate. For specimens undergoing SCC under applied potential in the active range, the ACGR increased with increasing the applied potential. The specimen eventually failed in a ductile manner when tested under an applied anodic potential in the passive range. The increase in the ACGR with increasing strain rate and the applied anodic potential is attributed to the enhanced dissolution at the crack tip. Moreover, secondary cracks formed when relatively high strain rates were used. The secondary cracks are believed to propagate mainly along the slip planes. The fracture surface morphology shows the {110} planes are the preferred fracture planes, with the fracture surface consisting of parallel facets separated by steps. Finally, the results indicate that hydrogen may play an indirect role in SCC.

Understanding crack growth within the γ′ Fe4N layer in a nitrided low carbon steel during monotonic and cyclic tensile testing

Nitriding is a cost-effective method to realize simultaneous improvements in tensile and fatigue properties and resistance to abrasion and corrosion. Previous studies reported that nitriding pure Fe enhances tensile strength by ~ 70% and fatigue limit by ~ 200%. It is due to the increase in surface hardness caused by the formation of γ′(Fe4N) and ε(Fe2-3N) nitrogen-containing intermetallic compound phases. However, the intermetallic compound layer is prone to brittle-like cracking. To better design nitrided steels, it is crucial to identify the crack growth mechanisms via analysis of the microstructural crack growth paths within the ~ 4–6 µm thick nitride layer. In the current work, we statistically evaluate the crack propagation behavior in the γ′ Fe4N layer during monotonic and cyclic tensile deformation in nitrided low-carbon steel (0.1 wt% C). Since nitriding typically results in the formation of columnar grains, the effect of morphology needs to be clarified. To this end, the steel was shot-peened and subsequently nitrided to promote equiaxed nitride grains morphology (~ 16% increase). Crack growth paths were comparatively evaluated for multiple cracks, and no significant effect of nitride morphology was observed. {100}γ′ is the predominant transgranular crack path in the monotonic tensile tested specimen, followed by {111}γ′. It is despite the elastic modulus of {111}γ′ < {100}γ′. This contrary behavior is explained by {100}γ′ plane having the lowest surface energy (density functional theory calculations). In the cyclic tensile loaded specimen, experiments revealed that transgranular cracking along {100}γ′ (cracking via symmetric dislocation emission) or {111}γ′ (slip plane cracking) is equally likely.Graphical abstract

Metallurgical failure investigation of small bore piping (SBP) in a diesel hydrotreating unit (DHT) of an oil refinery

Abstract Hydrocarbon leaks were repeatedly found in the client’s refinery. Because of the recurring nature of this failure, the operator approached the authors’ laboratory to get a second opinion on the metallurgical root cause of the failure. It was known from the customer that corrosive species, such as ammonium chloride salt precipitates, are present in the subject diesel hydrotreating unit (DHT). From the findings obtained in the investigation that is the subject of this contribution, the conclusion of the original metallurgical root cause analysis (RCA), namely that the subject piping failed by transgranular chloride-induced stress corrosion cracking (Cl-SCC), could be verified and is indeed correct. The metallurgical root cause of the small bore piping (SBP) failure is chloride-induced SCC. The morphology of the cracking is very distinct and is clearly consistent with transgranular Cl-SCC. A material change to the nickel-base material Alloy 625, already considered by the client, since this alloy is believed to be immune to chloride-induced SCC, would be a good, even though expensive solution. It should be emphasized that there are no metallic materials completely resistant to SCC. If the environment is harsh enough, except for some titanium alloys, i. e., if the source of the chloride ions cannot be eliminated, which is likely the case here, a regular inspection and replacement of these SBP systems might have to be considered. It should further be emphasized that a chloride concentration below 50 ppm is by no means any guarantee for the avoidance of SCC, since chlorides can concentrate in crevices, corrosion pits and such, i. e., the local concentration is what matters, not the local.

Insights into fatigue crack propagation mechanism of T91 steel in liquid lead-bismuth eutectic at 150–450 °C

The fatigue crack growth (FCG) behaviors of T91 steel in oxygen-saturated liquid lead–bismuth eutectic (LBE) at 150–450 °C were investigated. The FCG rate increased gradually with the increase of temperature at 150–350 °C, is firstly low at 450 °C and then comparable with that at 350 °C. The macroscopic trans-granular cracks preferentially propagated along the deformation-induced low-angle grain boundaries (LAGBs) near the crack tip at the microscopic scale. Intergranular precipitation-enhanced wetting of matrix by liquid LBE results in the reduction of atomic bonding force and formation of micro-cracks along the LAGBs, which triggers brittle cracking.

Failure analysis and preventative measures on cracking of tube-to-tubesheet joints of the large-scale heat exchanger

A large-scale heat exchanger in an EO/EG plant suffered a severe leakage failure after 3 years of service, and numerous fractures and cracks were found in the tube-to-tubesheet joints. A series of failure investigations, including macroscopic and microscopic inspection, physicochemical analysis, metallographic examination, and stress analysis, have been used to clarify the causes of cracking of tube-to-tubesheet joints. The macroscopic inspection revealed that the cracking of the joints occurred on the tube inlet side, and the fracture exhibited circumferential cracking. Scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS) presented that the fracture is a mixture of transgranular and intergranular cracking (predominantly intergranular), and the surface of the fracture is covered by corrosion products with chlorine, oxygen, and copper content. Furthermore, the stress analysis concluded that the joints were subjected to residual stresses, tensile stresses, and thermal stresses. Therefore, the cracking of the tube-to-tubesheet joints was caused by stress corrosion cracking (SCC), which originated from crevice corrosion and intergranular corrosion. Then, the corrosion mechanism involved in this failure was discussed in detail, and corresponding preventive measures were proposed. Achievements in this paper may supplement the failure database of tube-to-tubesheet joints in large-scale heat exchangers and reduce similar failures through engineering practices.

Microstructural Modification, Mechanical Properties, and Wear Behaviour of Aged Al-Si-Mg/Si3N4 Composites for Aerospace Applications

The main objective of the present research is to probe how ageing time influences the morphological, mechanical, and wear behaviour of stir cast Al-Si-Mg alloy, reinforced with 10 wt.% Si3N4 particles subsequently heat treated in T6 condition. The findings reveal that the presence of Si3N4 reinforcements, followed by the heat treatment, enhances the mechanical and tribological properties of the composite. The ensuing mechanical properties show significant improvement prior to aging heat treatment (180 °C/4h), reaching a hardness of 120.8 HV (45 % increase) and tensile strength of 275 MPa (50 % increment), respectively compared to as-cast composite. Fractography reveals dimples, transgranular cleavage surfaces, cracks, and micro-ploughing. Among the samples tested, the composite aged for 4 h (180 °C/4h, ASN-4) demonstrates the lowest wear rate. Abrasive and adhesive wear in combination is the primary wear mechanism in these samples. Overall, this research provides insights for research endeavors in manufacturing various components in the aerospace industry.

Analysis of physical and mechanical behaviors and microscopic mineral characteristics of thermally damaged granite

Temperature’s influence on the physical and mechanical properties of rocks is a crucial concern for the rational design of deep rock engineering structures and the assurance of their long-term stability. To systematically comprehend the impact of the evolution of mineral composition and micro characteristics on the physical and mechanical behavior of thermally damaged granite, we observed the microscopic structural defects inside the rocks with a polarizing microscope and revealed the thermal damage mechanism of granite from a microscopic perspective by combining ultrasound detection and XRD phase characteristic analysis. The results show that the physical properties of the specimens changed significantly at three characteristic temperature points: 400 °C, 800 °C, and 1000 °C. Under high temperature conditions, the diffraction intensity of all minerals in granite, except for quartz, generally decreased, and stable minerals decomposed. Albite and potash feldspar decomposed to form anorthoclase, thereby reducing the structural stability of the rock material. In addition, the peak width of various minerals decreased to varying degrees with increasing temperature. The increase in mineral volume further damaged the internal structure of the rock material while promoting the transformation from grain boundary to intergranular cracks and from intragranular cracks to transgranular cracks, ultimately forming a interconnected crack network. Thermal damage significantly reduced the longitudinal wave velocity, uniaxial compressive strength, and elastic modulus of the specimens, while the stress–strain curve relationship indicated that the specimens underwent two opposite processes of transformation from brittleness to ductility and then from ductility to brittleness. The thermal damage threshold of granite in this study was 600 °C.

In situ investigation of hydrogen embrittlement induced by δ phase in selective laser-melted GH4169 superalloy

Direct evidence of hydrogen-assisted crack nucleation and propagation associated with the δ phase in the selective laser melted GH4169 superalloy was obtained. The analysis of hydrogen trapping sites using thermal desorption spectroscopy revealed that the δ phase exhibits strong hydrogen capture capability, with a hydrogen desorption activation energy of 35.45 ± 2.51 kJ/mol. In addition, spatially resolved hydrogen mapping conducted by scanning Kelvin probe force microscopy and hydrogen microprint technique provided further evidence for the δ phase as a deep hydrogen trapping site. The atomic-scale characterization sufficiently reveals the deformation mechanism of the δ phase induced by dislocation accumulation. Hydrogen-promoted dislocation slip localization facilitates the formation of microvoid defects in the δ phase, which is the main reason for the δ phase fracture, and induces intergranular and transgranular cracks.