Fatigue crack propagation behavior of Ni-based superalloys after overloading at elevated temperatures

The fatigue crack propagation behavior of three superalloys subjected to a single overloading at elevated temperatures was investigated. The fatigue crack propagation rate FCPR versus stress intensity factor range data da/dN—ΔK were calculated using the two-point secant method. It was found that the crack growth rates of the investigated materials were retarded after overloading with an overload ratio R OL=1.6. The size of the plastic zone in the front of the crack tip and its relation to loading level were discussed. The overload retardation effects are attributed to crack closure. The fatigue damage in the plastic zone can also be a factor to explain the overload retardation.     

Effect of thermal aging on the fatigue crack growth behavior of cast duplex stainless steels

The effect of thermal aging on the fatigue crack growth (FCG) behavior of Z3CN20-09M cast duplex stainless steel with low ferrite content was investigated in this study. The crack surfaces and crack growth paths were analyzed to clarify the FCG mechanisms. The microstructure and micromechanical properties before and after thermal aging were also studied. Spinodal decomposition in the aged ferrite phase led to an increase in the hardness and a decrease in the plastic deformation capacity, whereas the hardness and plastic deformation capacity of the austenite phase were almost unchanged after thermal aging. The aged material exhibited a better FCG resistance than the unaged material in the near-threshold regime because of the increased roughness-induced crack closure associated with the tortuous crack path and rougher fracture surface; however, the tendency was reversed in the Paris regime because of the cleavage fracture in the aged ferrite phases.     

Isothermal grain growth of reactive spray formed 7075 alloys in semi-solid state

The grain growth behavior in reactive spray formed 7075+2.91vol%TiC Al alloy was studied and compared with that of spray formed 7075 Al alloy at semi-solid state. The effects of in-situ TiC particles on the microstructure of spray formed 7075 Al alloy were also investigated. The specimens were heat-treated isothermally at various temperatures between the solidus and liquidus of 7075 Al alloy for times in the range of 10-60 min, then quenched in water. The microstructure of reheated specimens was characterized using scanning electron microscopy and optical microscopy. The grain size was measured using a mean linear intercept method.Results show that the in-situ TiC particles can effectively retard grain growth and refine the grain at a limited size. The grain growth exponent in Arrhenius equation increases from 2 to 3, which indicates that the in-situ TiC particles have the significant pinning effect on grain coarsening in the semi-solid state.     

Corrosion fatigue behavior of fastening hole structure and virtual crack propagation tests

The fatigue crack propagation behavior of the LY12CZ aluminum alloy fastener involving a central hole in air or in 3.5wt% NaCl solution was investigated. The experimental results indicated that the corrosion fatigue crack growth rate decreased with the increasing loading frequency,and in a corrosive environment,the crack growth rate was slightly larger than that in air. Based on the experimental results,the virtual corrosion fatigue crack propagation tests were investigated and the stochastic process method and the AFGROW simulation method were presented. The normal process and lognormal process were considered for the stochastic process method based on the numerically fitted Paris equation. The distribution of crack size and the corresponding probabilistic model of crack length distribution for a given number of cycles can be found by integrating the stochastic process over time. Using the AFGROW software,the virtual simulation was carried out to analyze the corrosion fatigue crack growth behavior and the predicted crack growth curve was in good agreement with the experimental results.     

AA2198-T34合金搅拌摩擦焊的应力腐蚀行为及其特征

To better understand the stress-corrosion behavior of friction stir welding (FSW), the effects of the microstructure on the stress-corrosion behavior of the FSW in a 2198-T34 aluminum alloy were investigated. The experimental results show that the low-angle grain boundary (LABs) of the stir zone (SZ) of FSW is significantly less than that of heated affected zone (HAZ), thermo-mechanically affected zone (TMAZ), and parent materials (PM), but the grain boundary precipitates (GBPs) T1 (Al₂CuLi) were less, which has a slight effect on the stress corrosion. The dislocation density in SZ was greater than that in other regions. The residual stress in SZ was +67 MPa, which is greater than that in the TMAZ. The residual stress in the HAZ and PM is ?8 MPa and ?32 MPa, respectively, and both compressive stresses. The corrosion potential in SZ is obviously less than that in other regions. However, micro-cracks were formed in the SZ at low strain rate, which indicates that the grain boundary characters and GBPs have no significant effect on the crack initiation in the stress-corrosion process of the AA2198-T34. Nevertheless, the residual tensile stress has significant effect on the crack initiation during the stress-corrosion process.     

Corrosion behavior of cold-rolled and post heat-treated 316L stainless steel in 0.9wt%NaCl solution

The effect of cold rolling and post-rolling heat treatment on the microstructural and electrochemical properties of the 316L stainless steel was investigated.Two-pass and four-pass cold-rolled stainless steel specimens were heat-treated by annealing at 900℃followed by quenching in water.During the cold rolling,the microstructure of the as-received specimen transformed from austenite to strain-inducedα′-martensite due to significant plastic deformation that also resulted in significant grain elongation(i.e.,~33%and 223%increases in the grain elongation after two and four rolling passes,respectively).The hardness of the heat-treated as-received specimen decreased from HV 190 to 146 due to the recovery and recrystallization of the austenite grain structure.The cyclic polarization scans of the as-rolled and heat-treated specimens were obtained in 0.9wt%NaCl solution.The pitting potential of the four-pass rolled specimen was significantly increased from 322.3 to 930.5 mV after post-rolling heat treatment.The beneficial effect of the heat treatment process was evident from~10-times-lower corrosion current density and two-orders-of-magnitude-lower passive current density of the heat-treated specimens compared with those of the as-rolled specimens.Similarly,appreciably lower corrosion rate(3.302×10^?4mm/a)and higher pitting resistance(1115.5 mV)were exhibited by the postrolled heat-treated specimens compared with the as-rolled 316L stainless steel specimens.     

Deformation heterogeneity of Ti under cryogenic channel-die compression

Commercial purity Ti was subjected to channel die compression in liquid nitrogen for the purpose of studying its deformation characteristics from the viewpoint of the grain refinement induced by seve re plastic deformati on. Deformed specimens showed microstructural heterogeneity in that the initial blocky grains of about 50 μm in size turned into a mixture of the easily deforming soft grains and the hard grains revealing local concentration of dislocati ons and deformation twins. Using electron back scattered diffraction analysis the in-grain misorientation-axis distribution was studied, from which it was found that the deformation heterogeneity resulted from the anisotropy of individual grains with respect to the compression die: while the soft grains were those oriented favorably for the prism < a> slip, the hard ones were oriented for non-prism slips and deformation twinning. The difference in the response of individual grains, therefore, led to a remarkable effect of the crystal texture of specimens on the maximum strain that can be imposed on specimens without cracking. Based on the present results, a way to achieve expedient grain refinement through the cryogenic plane-strain compression was suggested.     

Effect of homogenization process on the hardness of Zn–Al–Cu alloys

The effect of a homogenizing treatment on the hardness of as-cast Zn–Al–Cu alloys was investigated. Eight alloy compositions were prepared and homogenized at 350 ℃ for 180 h, and their Rockwell “B” hardness was subsequently measured. All the specimens were analyzed by X-ray diffraction and metallographically prepared for observation by optical microscopy and scanning electron microscopy. The results of the present work indicated that the hardness of both alloys (as-cast and homogenized) increased with increasing Al and Cu contents; this increased hardness is likely related to the presence of the θ and τ' phases. A regression equation was obtained to determine the hardness of the homogenized alloys as a function of their chemical composition and processing parameters, such as homogenization time and temperature, used in their preparation.     

Corrosion behavior of cold-rolled and post heat-treated 316L stainless steel in 0.9wt% NaCl solution

The effect of cold rolling and post-rolling heat treatment on the microstructural and electrochemical properties of the 316 L stainless steel was investigated. Two-pass and four-pass cold-rolled stainless steel specimens were heat-treated by annealing at 900°C followed by quenching in water. During the cold rolling, the microstructure of the as-received specimen transformed from austenite to strain-induced α′-martensite due to significant plastic deformation that also resulted in significant grain elongation(i.e., ～33% and 223% increases in the grain elongation after two and four rolling passes, respectively). The hardness of the heat-treated as-received specimen decreased from HV 190 to146 due to the recovery and recrystallization of the austenite grain structure. The cyclic polarization scans of the as-rolled and heat-treated specimens were obtained in 0.9 wt% Na Cl solution. The pitting potential of the four-pass rolled specimen was significantly increased from 322.3 to 930.5 m V after post-rolling heat treatment. The beneficial effect of the heat treatment process was evident from ～10-times-lower corrosion current density and two-orders-of-magnitude-lower passive current density of the heat-treated specimens compared with those of the as-rolled specimens. Similarly, appreciably lower corrosion rate(3.302 × 10~(-4) mm/a) and higher pitting resistance(1115.5 m V) were exhibited by the postrolled heat-treated specimens compared with the as-rolled 316 L stainless steel specimens.     

Solid-particle erosion behavior of cast alloys used in the mining industry

The erosive-wear response of five commercial ferrous-based cast alloys used for crushing was examined in this study. The micro-structures of the alloys were modified to elucidate the effect of microstructural features on wear. Erosion tests were conducted using alumi-num oxide particles (90–125 μm) at 70 m/s and a normal impact angle (90°). The worn surfaces were characterized by scanning electron mi-croscopy and 3D non-contact laser profilometry. It is found that (i) a pearlitic structure exhibiting a greater plastic deformation than both bainitic and martensitic structures shows the greatest resistance to erosive wear at normal impact and (ii) the fracture characteristics of car-bide and graphite particles plays an important role in determining the erosion wear behavior of the cast alloy matrices.     

Anodic dissolution of a crack tip at AA2024-T351 in 3.5wt% NaCl solution

The anodic dissolution process of a crack tip at 2024-T351 aluminium alloy (AA2024-T351) was determined by means of scanning Kelvin probe (SKP). Wedge-open loading (WOL) specimens were immersed in a 3.5wt% NaCl solution. After various durations of immersion, the Volta potential distributions around the crack were measured by SKP and the surface morphologies were observed by scanning electron microscopy (SEM). It is found that there is a nonuniform distribution of Volta potential around the crack. Before immersion, the Volta potential at crack tip is more negative than that in other regions. However, after immersion, a converse result occurs with the most positive Volta potential measured at the crack tip. SEM observations demonstrate that the noticeable positive shift of Volta potential results from the formation of corrosion products which deposit around the crack tip. Energy-dispersive spectrometry (EDS) analysis shows that the corrosion products are mainly Al oxide and Cu-rich particles. These observations implicate that the applied stress contributes to the preferential anodic dissolution of the crack tip and the redistribution of Cu.     

Reinforcing effect of laminate structure on the fracture toughness of Al3Ti intermetallic

Metal/intermetallic laminate composites can improve the mechanical properties of intermetallic materials using metal layers. In recent years, titanium aluminide intermetallics have received increasing attention due to their excellent performance properties, such as high melting point, high specific strength and stiffness, and good corrosion resistance. However, the low fracture toughness of Al3Ti alloys at room temperature has greatly limited their application, and fiber or particle reinforcement has not shown a significant toughening effect. Research into the reinforcing effects of the interface and near-interface zone on the fracture behavior of Al3Ti is lacking. Ti/Al3Ti metal/intermetallic laminate composite was synthesized from titanium and aluminum foils using vacuum hot-pressed sintering technology. The microstructure of the prepared material was analyzed by scanning electron microscope and electron backscattered diffraction. Results illustrate that both Ti and Al3Ti were single-phase and there was a noticeable stress concentration on the interface. To obtain indentation and cracks, loads were applied to different locations of the composite by a microhardness tester. The growth path of the cracks was then observed under microscope, showing that crack propagation was prevented by the interface between the Ti and Al3Ti layers, and the cracks that propagated parallel to the laminate shifted to the interface. Fracture toughness of the different areas, including Al3Ti layers, interface, and near-interface zone, were measured by the indentation fracture method. The fracture toughness at and near the interface was 1.7 and 2 times that of the Al3Ti layers, respectively. Results indicate that crack blunting and crack front convolution by the laminate structure was primarily responsible for increased toughness.     

Effect of heat treatment on the microstructure and mechanical properties of structural steel–mild steel composite plates fabricated by explosion welding

Two dissimilar steel plates, structural steel and mild steel, were joined by explosion welding to form a composite. The composite was then heat-treated by quenching at 840°C for 30 min followed by tempering at 200°C for 3 h. The microstructure was investigated under an optical microscope and a scanning electron microscope. The mechanical properties were measured using Vickers microhardness and Charpy impact tests. The results show a deformed interface with typical wave features at the welding zone, but no defects were observed. Moreover,the ferrite in the parent plate in the weld zone was elongated due to the strong plastic deformation from the explosion. After heat treatment, the hardness of the flyer plate(structural steel) was over HV0.2 800, while that of the parent plate(mild steel) was HV0.2 200. The increase in hardness was due to the presence of martensite. Moreover, the average impact energy was increased from 18.5 to 44.0 J following heat treatment;this is because of the formation of recrystallized grains at the weld interface, which is due to the dynamic recovery and local recrystallization,and the strong elemental diffusion that occurred between the two plates.     

SEM in-situ investigation on fatigue cracking behavior of P/M Rene95 alloy with surface inclusions

The low-cycle fatigue behavior of powder metallurgy Rene95 alloy containing surface inclusions was investigated by in-situ observation with scanning electron microscopy (SEM). The process of fatigue crack initiation and early stage of propagation behavior indicates that fatigue crack mainly occurs at the interface between the inclusion and the matrix. The effect of inclusion on the fatigue crack initiation and the early stage of crack growth was very obvious. The fatigue crack growth path in the matrix is similar to the shape of inclusion made on the basis of fatigue fracture image analysis. The empiric relation between the surface and inside crack growth length, near a surface inclusion, can be expressed. Therefore, the fatigue crack growth rate or life of P/M Rene95 alloy including the inclusions can be evaluated on the basis of the measurable surface crack length parameter. In addition, the effect of two inclusions on the fatigue crack initiation behavior was investigated by the in-situ observation with SEM.     

Microstructural characteristics and mechanical properties of bobbin-tool friction stir welded 2024-T3 aluminum alloy

Cold-rolled 2024-T3 sheet alloy was subjected to bobbin-tool friction stir welding (BTFSW). The microstructural characteristics and mechanical properties of the nugget zone in the as-welded state were investigated. The results show that the equiaxed grain size of BTFSW 2024-T3 alloy decreases from 7.6 to 2.8 μm as the welding speed is increased from 80 to 120 mm/min; in addition, fine grains are generated in the nugget zone and the size distribution is non-uniform. All Al₂CuMg (S') precipitates dissolve into the Al matrix, whereas Mn-rich phases confirmed as T phases (Al₂₀Cu₂Mn₃, Al₆Mn, or Al₃Mn) remain unchanged. The optimized parameters for BTFSW are verified as the rotation speed of 350 r/min and the travel speed of 100 mm/min. The variations in precipitation and dislocation play more important roles than grain size in the nugget zone with respect to influencing the mechanical properties during the BTFSW process. After the BTFSW process, the fracture mode of base material 2024-T3 alloy transforms from ductile rupture to ductile-brittle mixed fracture.     

Microstructural analyses of aluminum–magnesium–silicon alloys welded by pulsed Nd: YAG laser welding

Revealing grains and very fine dendrites in a solidified weld metal of aluminum–magnesium–silicon alloys is difficult and thus,there is no evidence to validate the micro-and meso-scale physical models for hot cracks. In this research, the effect of preheating on the microstructure and hot crack creation in the pulsed laser welding of AA 6061 was investigated by an optical microscope and field emission electron microscopy. Etching was carried out in the gas phase using fresh Keller's reagent for 600 s. The results showed that the grain size of the weld metal was proportional to the grain size of the base metal and was independent of the preheating temperature. Hot cracks passed the grain boundaries of the weld and the base metal. Lower solidification rates in the preheated samples led to coarser arm spacing; therefore, a lower cooling rate. Despite the results predicted by the micro and meso-scale models, lower cooling rates resulted in increased hot cracks. The cracks could grow in the weld metal after solidification; therefore, hot cracks were larger than predicted by the hot crack prediction models.     

Effects of thermal aging temperature and Cr content on phase separation kinetics in Fe-Cr alloys simulated by the phase field method

Phase field simulations of phase separation in Fe-Cr binary alloys were performed by using the Cahn-Hilliard diffusion function. A new mobility model in relation to aging temperature and Cr content was used in the simulations. Two alloys of Fe-30at%Cr and Fe-35at%Cr were investigated at two different aging temperatures of 573 and 673 K. The phase separation kinetics was found to consist of three stages: wavelength modulation, amplitude increase, and coarsening of Cr-enriched regions. A higher thermal aging temperature accelerated the phase separation and increased the wavelength of concentration fluctuation. While the effect of Cr content on the phase separation kinetics was slight, Fe-Cr alloys with a higher Cr content were found to generate a larger number and a finer size of Cr-enriched regions. The simulation results provide consultation for design and safe operation of duplex stainless steel pipes in nuclear power plants.     

Affected zone generated around the erosion pit on carbon steel surface at the incipient stage of vibration cavitation

The characteristics of erosion pits on a carbon steel surface were investigated at the incipient stage of cavitation erosion. After a 5-minute experiment performed in an ultrasonic vibration system, needle-like erosion pits appeared on the polished steel surface, and a specially affected zone was formed around the pit. The shape of the pit and the plastic deformation of the affected zone indicate that the me-chanical impaction on the surface is the main reason for the cavitation damage. On the other hand, the iridescent color, the decreased surface hardness and the precipitated carbides on the affected zone prove that the affected zone has experienced a tempering process with the temperature higher than 300℃. The lack of oxygen in the affected zone also proves that it is not a chemical oxygen result. A special phenomenon that a carbon ring forms in the affected zone is explained as a result of the tor- oidal bubbles＇ heating effect at the final stage of the bubble collapse.     

Strain localization and damage development in 2060 alloy during bending

The microstructure evolution and damage development of the third-generation Al–Li alloy 2060 (T8) were studied using in situ bending tests. Specimens were loaded with a series of punches of different radii, and the microstructure evolution was studied by scanning electron microscopy, electron backscatter diffraction, and digital image correlation (DIC) methods. The evolution of the microscopic fracture strain distribution and microstructure in 2060 alloy during bending was characterized, where the dispersion distribution of precipitates was recorded by backscattered electron imaging and later inputted into a DIC system for strain calculations. The experimental results showed that strain localization in the free surface of bent specimens induced damage to the microstructure. The region of crack initiation lies on the free surface with maximum strain, and the shear crack propagates along the macro-shear band in the early stages of bending. Crack propagation in the later stages was interpreted on the basis of the conventional mechanism of ductile fracture.     

Crack spacing of unsaturated soils in the critical state

The cracking mechanism of unsaturated soils due to evaporation is poorly understood, and the magnitude of crack spacing is usually hard to estimate. In this work, cracks were postulated to occur succedently rather than simultaneously, that is, secondary cracks appear after primary cracks as evaporation continues. Formulae of the secondary crack spacing and secondary trend crack spacing were then derived after stress analysis. The calculated spacing values were consistent with the published experimental data. Meanwhile, the effect of the Poisson ratio on the crack spacing was analyzed, which showed that the magnitude of crack spacing was proportional to the Poisson ratio in the range of [0.30, 0.35].