Effect of microstructure on fatigue crack propagation in additive manufactured nickel-based superalloy Haynes 282: an experiment and crystal plasticity study

Jiahao Cheng, Patxi Fernandez-Zelaia, Xiaohua Hu, Michael Kirka

Research output: Contribution to journalArticlepeer-review

14 Scopus citations

Abstract

Haynes 282 is a γ precipitation-strengthened nickel-based superalloy known for its exceptional high-temperature creep resistance and excellent fabricability. Recent advancements in powder-bed fusion-based additive manufacturing (PBF-AM) have enabled the fabrication of Haynes 282 with accurate, site-specific control of the grain orientation and morphology at the microscale. This ability opens up new avenues for microstructure design, to improve the material’s fatigue crack resistance and service life. This paper investigates the fatigue crack growth behavior of hybrid microstructure Haynes 282 fabricated via PBF-AM. Previous experiments revealed a higher crack propagation rate in the coarse columnar-grained microstructural regions when compared against fine-grained areas. Here, a strain gradient crystal plasticity model was adapted to study the fracture-related mechanical fields at the crack tip in the two microstructures. The simulation results showed a consistent influence of grain structure and texture on crack propagation, as was seen in the experiment. The model analysis revealed higher crack propagation driving force along crack direction in the coarse-grained sharply textured microstructure and higher driving force for crack kinking in fine-grained more diffusely textured microstructure, which is ascribed to the combined effect of yield stress, hardening rate, texture and grain morphology. The presented modeling approach will facilitate the development of the AM-based accurate microstructure design by deepening the fundamental study in AM-specific microstructure-properties relations.

Original languageEnglish
Pages (from-to)9741-9768
Number of pages28
JournalJournal of Materials Science
Volume57
Issue number21
DOIs
StatePublished - Jun 2022

Funding

This research was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT- Battelle LLC and performed at the Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, an Office of Energy Efficiency and Renewable Energy user facility. This manuscript has been authored in part by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ). This research was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT- Battelle LLC and performed at the Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, an Office of Energy Efficiency and Renewable Energy user facility. This manuscript has been authored in part by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

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