Skip to main content
SpringerLink
Log in

Comparative study of small crack growth behavior between specimens with and without machining-induced residual stress of alloy GH4169

  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

We investigated the small fatigue crack behavior of alloy GH4169 by using single-edge-notch tension specimens. Residual stress introduced by machining process was taken into consideration, and two stress levels were selected. A comparison was made between the experimental results of specimens with and without machining-induced residual stress. The results indicated that fatigue cracks of the two types of specimens initiated from surface inclusions or grain boundaries. For both types of specimens, small cracks grew very slowly when the crack lengths were less than 500 μm. The small crack growth might decelerate and retard temporarily for the existence of grain boundaries. The residual stress effect on crack growth can be identified at σmax = 380 MPa, i.e., compressive residual stress might impede the crack growth. However, this phenomenon was indistinguishable at σmax = 410 MPa.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. S. Suresh and R. O. Ritchie, Propagation of short fatigue cracks, International Metals Reviews, 29 (6) (1984) 445–475.

    Google Scholar 

  2. K. J. Miller, The behavior of short fatigue cracks and their initiation Part II–a general summary, Fatigue & Fracture of Engineering Materials & Structures, 10 (2) (1987) 93–113.

    Article  Google Scholar 

  3. M. Okazaki, H. Yamada and S. Nohmi, Temperature dependence of the intrinsic small fatigue crack growth behavior in Ni–base superalloys based on measurement of crack closure, Metallurgical and Materials Transactions A, 27A (4) (1996) 1021–1031.

    Google Scholar 

  4. R. Jiang, N. Karpasitis, N. Gao and P. A. S. Reed, Effect of microstructures on fatigue crack initiation and short crack propagation at room temperature in an advanced disc superalloy, Materials Science and Engineering: A, 641 (8) (2015) 148–159.

    Article  Google Scholar 

  5. M. D. Sangid, H. J. Maier and H. Sehitoglu, A physically based fatigue model for prediction of crack initiation from persistent slip bands in polycrystals, Acta Materialia, 59 (1) (2011) 328–341.

    Article  Google Scholar 

  6. D. L. McDowell and F. P. E. Dunne, Microstructuresensitive computational modeling of fatigue crack formation, International J. of Fatigue, 32 (9) (2010) 1521–1542.

    Article  Google Scholar 

  7. X. R. Wu, J. C. Newman, W. Zhao, M. H. Swain, C. F. Ding and E. P. Phillips, Small crack growth and fatigue life predictions for high–strength aluminum alloys: Part I–experimental and fracture mechanics analysis, Fatigue & Fracture of Engineering Materials & Structures, 21 (11) (1998) 1289–1306.

    Article  Google Scholar 

  8. S. Suresh, Fatigue of materials, Cambridge University Press, London, UK (1998).

    Book  Google Scholar 

  9. A. Thomas, M. El–Wahabi, J. M. Cabrera and J. M. Prado, High temperature deformation of Inconel 718, J. of Materials Processing Technology, 177 (1) (2006) 469–472.

    Article  Google Scholar 

  10. N. Späth, V. Zerrouki, P. Poubanne and J. Y. Guedou, 718 superalloy forging simulation: a way to improve process and material potentialities, Superalloys 718, 625, 706 and Various Derivatives, TMS, Warrendale (2001) 173–183.

    Google Scholar 

  11. F. Alexandre, S. Deyber and A. Pineau, Modelling the optimum grain size on the low cycle fatigue life of a Ni based superalloy in the presence of two possible crack initiation sites, Scripta Materialia, 50 (1) (2004) 25–30.

    Article  Google Scholar 

  12. M. Goto, T. Yamomoto, N. Kawagoishi and H. Nisitani, Growth behavior of small surface cracks in Inconel 718 superalloy, International Conference on Temperature–Fatigue Interaction, Ninth International Spring Meeting, European Structural Integrity Society, Paris (2002) 237–246.

    Google Scholar 

  13. T. Connolley, P. A. S. Reed and M. J. Starink, Short crack initiation and growth at 600 °C in notched specimens of Inconel 718, Materials Science and Engineering: A, 340 (1) (2003) 139–154.

    Article  Google Scholar 

  14. X. Y. Huang, H. C. Yu, M. Q. Xu and Y. X. Zhao, Experimental investigation on microcrack initiation process in nickel–based superalloy DAGH4169, International J. of Fatigue, 42 (4) (2012) 153–164.

    Article  Google Scholar 

  15. G. J. Deng, S. T. Tu, X. C. Zhang, Q. Q. Wang and C. H. Qin, Grain size effect on the small fatigue crack initiation and growth mechanisms of nickel–based superalloy GH4169, Engineering Fracture Mechanics, 134 (2015) 433–450.

    Article  Google Scholar 

  16. C. H. Qin, X. C. Zhang, S. Ye and S. T. Tu, Grain size effect on multi–scale fatigue crack growth mechanism of Nickel–based alloy GH4169, Engineering Fracture Mechanics, 142 (2015) 140–153.

    Article  Google Scholar 

  17. G. J. Deng, S. T. Tu, X. C. Zhang, J. Wang, C. C. Zhang, X. Y. Qian and Y. N. Wang, Small fatigue crack initiation and growth mechanisms of nickel–based superalloy GH4169 at 650 °C in air, Engineering Fracture Mechanics, 153 (2016) 35–49.

    Article  Google Scholar 

  18. A. Javidi, U. Rieger and W. Eichlseder, The effect of machining on the surface integrity and fatigue life, International J. of Fatigue, 30 (10) (2008) 2050–2055.

    Article  Google Scholar 

  19. A. M. Abrao and D. K. Aspinwall, The surface integrity of turned and ground hardener bearing steel, Wear, 196 (1) (1996) 279–284.

    Article  Google Scholar 

  20. D. W. Schwach and Y. B. Guo, A fundamental study on the impact of surface integrity by hard turning on rolling contact fatigue, International J. of Fatigue, 28 (12) (2006) 1838–1844.

    Article  Google Scholar 

  21. S. Smith, S. N. Melkote, E. Lara–Curzio, T. R. Watkins, L. Allard and L. Riester, Effect of surface integrity of hard turned AISI 52100 steel on fatigue performance, Materials Science and Engineering: A, 459 (1) (2007) 337–346.

    Article  Google Scholar 

  22. L. Zhu, Z. R. Wu, X. T. Hu and Y. D. Song, Investigation of small fatigue crack initiation and growth behavior of nickel base superalloy GH4169, Fatigue & Fracture of Engineering Materials & Structures, 39 (9) (2016) 1150–1160.

    Article  Google Scholar 

  23. A. R. C. Sharman, J. I. Hughes and K. Ridgway, An analysis of the residual stresses generated in Inconel 718TM when turning, J. of Materials Processing Technology, 173 (3) (2006) 359–367.

    Article  Google Scholar 

  24. Y. K. Gao and X. R. Wu, Experimental investigation and fatigue life prediction for 7475–T7351 aluminum alloy with and without shot peening–induced residual stresses, Acta Materialia, 59 (9) (2011) 3737–3747.

    Article  Google Scholar 

  25. J. B. Jordon, J. D. Bernard and J. C. Newman, Quantifying microstructurally small fatigue crack growth in an aluminum alloy using a silicon–rubber replica method, International J. of Fatigue, 36 (1) (2012) 206–210.

    Article  Google Scholar 

  26. U. Zerbst, M. Madia and D. Hellmann, An analytical fracture mechanics model for estimation of S–N curves of metallic alloys containing large second phase particles, Engineering Fracture Mechanics, 82 (2012) 115–134.

    Article  Google Scholar 

  27. W. Elber, Fatigue crack closure under cyclic tension, Engineering Fracture Mechanics, 2 (1) (1970) 37–45.

    Article  Google Scholar 

  28. K. D. Singh, M. R. Parry and I. Sinclair, A short summary on finite element modelling of fatigue crack closure, J. of Mechanical Science and Technology, 25 (12) (2011) 3015–3024.

    Article  Google Scholar 

  29. Z. W. Gao, K. Y. Lee and Y. H. Zhou, Crack tip shielding and anti–shielding effects of parallel cracks for a superconductor slab under an electromagnetic force, J. of Mechanical Science and Technology, 26 (2) (2012) 353–357.

    Article  Google Scholar 

  30. R. Strubbia, S. Hereñú, A. Giertler, I. Alvarez–Armas and U. Krupp, Experimental characterization of short crack nucleation and growth during cycling in lean duplex stainless steels, International J. of Fatigue, 65 (2014) 58–63.

    Article  Google Scholar 

  31. U. Krupp and I. Alvarez–Armas, Short fatigue crack propagation during low–cycle, high cycle and very–high–cycle fatigue of duplex steel–An unified approach, International J. of Fatigue, 65 (2014) 78–85.

    Article  Google Scholar 

  32. J. C. Newman, The merging of fatigue and fracture mechanics concepts: A historical perspective, Progress in Aerospace Sciences, 34 (5) (1998) 347–390.

    Article  Google Scholar 

  33. L. Zhang and X. R. Wu, Fatigue life prediction method based on small crack theory in GH4169 superalloy, J. of Aeronautical Materials, 34 (6) (2014) 75–83.

    Google Scholar 

  34. C. J. Lammi and D. A. Lados, Effects of residual stresses on fatigue crack growth behavior of structural materials: Analytical corrections, International J. of Fatigue, 33 (7) (2011) 858–867.

    Article  Google Scholar 

  35. J. E. LaRue and S. R. Daniewicz, Predicting the effect of residual stress on fatigue crack growth, International J. of Fatigue, 29 (3) (2007) 508–515.

    Article  Google Scholar 

  36. J. Schijve, Fatigue of structures and materials in the 20th century and the state of the art, International J. of Fatigue, 25 (8) (2003) 679–702.

    Article  MATH  Google Scholar 

  37. Y. S. Hong, Y. Qiao, N. Liu and X. Zheng, Effect of grain size on collective damage of short cracks and fatigue life estimation for a stainless steel, Fatigue & Fracture of Engineering Materials & Structures, 21 (11) (1998) 1317–1325.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Jiangsu Province Key Laboratory of Aerospace Power System, College of Energy and Power Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Lei Zhu, Zhirong Wu, Xuteng Hu & Yingdong Song

  2. State Key Laboratory of Mechanics and Control of Mechanical Structures, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Yingdong Song

Authors
  1. Lei Zhu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhirong Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xuteng Hu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yingdong Song
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yingdong Song.

Additional information

Recommended by Editor Chongdu Cho

Lei Zhu is currently a Ph.D. candidate at College of Energy and Power Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China. He received his B.S. in Aircraft Power Engineering from Nanjing University of Aeronautics and Astronautics, Nanjing, China, in 2013. His research interests include foreign object damage and the subsequent fatigue crack behavior in aero-engine materials.

Xuteng Hu is currently a Lecturer at College of Energy and Power Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China. His research interests include deformation, fracture and fatigue behavior in metals and aero-engine structures, and foreign object damage in fan/compressor blades.

Yingdong Song is currently a Professor at College of Energy and Power Engineering and State Key Laboratory of Mechanics and Control of Mechanical Structures, Nanjing University of Aeronautics and Astronautics, Nanjing, China. His research interests include strength design, fatigue prediction and reliability analysis of aero-engine structures.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhu, L., Wu, Z., Hu, X. et al. Comparative study of small crack growth behavior between specimens with and without machining-induced residual stress of alloy GH4169. J Mech Sci Technol 32, 5251–5261 (2018). https://doi.org/10.1007/s12206-018-1023-x

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-018-1023-x

Keywords

Search

Navigation