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Dwell-Fatigue of Ni-Based Superalloys with Serrated and Planar Grain Boundary Morphologies: The Role of the γ′ Phase on Strain Accumulation and Cavitation

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Abstract

The effect of grain boundary (GB) morphology on the cavitation behavior in a Ni-based superalloy, RR1000, was studied during elevated temperature dwell-fatigue at 700 °C. Following a solution heat treatment, the material was control cooled at two different rates, resulting in high angle GB morphologies that were tailored as either serrated or planar. The resulting γ′ precipitate structures were characterized near GBs and within grains. Along serrated GBs coarsened and elongated γ′ precipitates formed and consequently created adjacent regions that were denuded of γ′ precipitates. Cyclic dwell-fatigue experiments were performed at low and high stress amplitudes to vary the amount of imparted strain on the specimens. A combination of electron backscatter diffraction and digital image correlation were used to resolve strain localization relative to the GBs, in which strain accumulation was found to precede cavity formation. Additionally, the regions denuded of the γ′ precipitates were observed to localize strain and to be initial sites of cavitation. These results present a quantitative strain analysis between two variants of an RR1000 alloy, which provides the micromechanical rationale to assess the increased proclivity for serrated GBs to form cavities.

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Acknowledgments

Financial support of the dwell fatigue and cavitation analysis at serrated grain boundaries was provided by the National Science Foundation (Grant Number CMMI 13-34664) and Rolls-Royce Corporation. Partial support for J.R. was provided by the Department of Defense through the National Defense Science and Engineering Graduate Fellowship Program (NDSEG). The grain boundary sliding analysis and time commitment of A.V. was supported by The U.S. Department of Energy, Office of Basic Energy Sciences, Division of Materials Sciences and Engineering (Award #DE-SC0014281).

Conflict of interest

The authors declare that they have no conflicts of interest.

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Author notes

  1. Alberto W. Mello

    Present address: Aerospace Engineering Department, Embry-Riddle Aeronautical University, Daytona Beach, USA

Authors and Affiliations

  1. School of Materials Engineering, Purdue University, 701 W. Stadium Ave, West Lafayette, IN, 47907, USA

    John Rotella & Michael D. Sangid

  2. Air Force Research Lab, Materials and Manufacturing Directorate, AFRL/RXCM, Wright Patterson AFB, Dayton, OH, 45433, USA

    John Rotella

  3. School of Aeronautics and Astronautics, Purdue University, 701 W. Stadium Ave., West Lafayette, IN, 47907, USA

    Alberto W. Mello, Ajey Venkataraman & Michael D. Sangid

  4. Rolls-Royce plc, Derby, DE24 8BJ, UK

    Ross Buckingham & Mark Hardy

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Correspondence to Michael D. Sangid.

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Manuscript submitted August 17, 2021; accepted Sep 1, 2021.

Appendix

Appendix

To minimize the effect of trackable features on the strain measurement, a sensitivity study of the subset size versus the standard deviation of axial strain was conducted on all specimens before a subset and step size were chosen to perform the DIC strain analysis. The sensitivity analysis was performed using two images, taken one after another on a non-deformed specimen within the AOI. The subset size and the standard deviation of strain share an inverse relationship. This relationship was established for these images and only subset and step sizes resulting in a standard deviation of less than 0.1 pct are deemed acceptable.[49] An image of one field of view is shown below. The six squares within the bounding box represent examples of the 1.23 µm subset. A magnified view of example subsets can be seen within Figure 15 (b).

Fig. 15
figure 15

(a) One field of view of an area of interest with a fiducial marker. (b) enlarged inset showing the 1.23 µm subset, relative to the trackable features via DIC

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Rotella, J., Mello, A.W., Venkataraman, A. et al. Dwell-Fatigue of Ni-Based Superalloys with Serrated and Planar Grain Boundary Morphologies: The Role of the γ′ Phase on Strain Accumulation and Cavitation. Metall Mater Trans A 52, 5079–5095 (2021). https://doi.org/10.1007/s11661-021-06454-8

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