Fatigue life assessment of a porous casting nickel-based superalloy based on fracture mechanics methodology

Pang, Keji; Yuan, Huang

doi:10.1016/j.ijfatigue.2020.105575

Cited by 15 publications

(4 citation statements)

References 44 publications

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“…Simulation studies: any study in which simulations were performed in order to reproduce or simulate different casting features, grain structures, skin formation, like the progression of S/L interface, shape of liquidus isotherm, etc. [2,8,36,37,41,42,54,56,[60][61][62][63][64][65][66][67][68] 2 Prediction studies: any study in which various methods were used for predicting the features of the cast specimens like pore size, freckle formation, grain structure, grain size, and fatigue life [9,17,20,28,37,41,43,58,69] 3 Conventional investment casting (Bridgman furnace): any study that focuses on the conventional casting process where a Bridgman furnace is used [16,[44][45][46]70] 4 LMC process: any study in which LMC process was used or was talked about in depth [1,30,35,36,71] Advances in Materials Science and Engineering HRS process: any study in which HRS process was used or was talked about in depth [8,30,36,71] 6…”

Section: Research Areamentioning

confidence: 99%

“…Freckles: any study that talks about the formation of freckles, the harm they do, and how freckling can be avoided [5, 8, 26-28, 35, 42, 85, 90-93] Hot tears: any study that talks about the formation of hot tears, the harm they do, and how hot tears can be avoided [7,29,38,40,94] Porosities: any study that talks about the formation of porosities, the harm they do, and how they can be avoided [20,21,25,34,37,39,43,50,54,76] Slivers: any study that talks about the formation of sliver defects, the harm they do, and how they can be avoided [16,68] Fatigue properties: any study that deals with the different fatigue properties like fatigue life and behaviour of various superalloys [1-3, 11-14, 20-22, 30, 41, 43, 47, 58, 67, 74, 86, 95, 96] Creep properties: any study that deals with the different creep properties like creep life and behaviour of various superalloys [1,12,18,19,23,31,41,51,74,77,78] Stress/strain properties: any study that deals with the stress/strain properties like stress relaxation and rupture behaviour of various superalloys [2, 12, 13, 22-25, 33, 37, 41, 45, 47, 52, 54, 55, 57, 58, 74, 88] Grain selection: any study that talks in depth about the grain selection/competitive growth process that takes place when selecting a single grain while producing SX components [4,6,36,49,56,62,85,…”

Section: Research Area Papers Pertaining To the Respective Areamentioning

confidence: 99%

“…And as far as fatigue life of casting parts was concerned, it is seen to be heavily dependent on the size and location of the defects. One study [43] particularly focused on this. K465, a polycrystalline Ni-based superalloy, was used to make samples to work with for this study.…”

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Recent Advancements in the Field of Ni‐Based Superalloys

Selvaraj

Sundaramali

Dev

et al. 2021

Advances in Materials Science and Engineering

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In this review article, research papers related to recent developments in Ni-superalloy technologies have been reviewed in order to provide an insight into recent achievements and the potential for further study, research, and development in this field. In this paper, studies on various aspects of Ni-based superalloys are reviewed, such as production methods, which include widely used casting methods, as well as unconventional alternative procedures, novel techniques, or simulation and prediction of certain alloy casting properties. Reviewing was done by categorising the papers into 4 major categories: manufacturing of Ni-based superalloys, effects of alloying elements, physical and mechanical properties of Ni-based superalloys, and defects in Ni-based superalloys. The process used to make Ni-superalloy parts can have a huge impact on the production process efficiency, the final product’s quality and properties, and the defects formed in it. Investment casting is one of the most common methods for making Ni-superalloy parts. Manufacturing covers studies on various casting methods used to make Ni-based superalloy components, novel techniques and methods developed to improve casting procedures to produce better products, and alternative manufacturing methods like AM and HIP processing. Similar to production process, the role of alloying elements is also very important. Even minor changes in their compositions can cause significant changes in the final product. Simultaneously, these alloying elements appear to be more efficient in the development of new methods to control product quality, suppress defect formation, and improve material properties such as the creep and fatigue. As a result, the effects of various alloying elements used in castings of Ni-based superalloys are thoroughly examined. A material’s properties are its most important components. They assist the industrialist in selecting or developing a material based on the needs of the application/use. With this in mind, many researchers have conducted extensive research on physical and mechanical properties, as well as how to improve them. Fatigue life, stress rupture, creep properties, impact ductility, strain response, stress relaxation behaviour, and so on are some of the most important physical and mechanical properties of Ni-superalloys. This article thoroughly reviews various studies on these properties, how and by what factors they are affected, and how they can be improved. Another important factor to consider when making Ni-superalloy castings is defect formation, which can affect the properties of the final product. Freckle defects, hot tears, porosities, and slivers are some of the major defects that occur in Ni-superalloys during the casting process. This article also reviews in detail about these defects, how they form, and how they affect the final product. These defects were found to have a significant influence on a variety of properties, such as creep, fatigue behaviour, and fracture mechanism. Topics and areas such as reinforcement of Ni-superalloys with the help of CNCs and 3D printing of Ni-superalloys that can provide scope for potential future research are highlighted based on the above-reviewed papers.

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Section: Research Areamentioning

confidence: 99%

Section: Research Area Papers Pertaining To the Respective Areamentioning

confidence: 99%

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Recent Advancements in the Field of Ni‐Based Superalloys

Selvaraj

Sundaramali

Dev

et al. 2021

Advances in Materials Science and Engineering

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“…However, the service performance of superalloy parts obtained by traditional casting technology is affected by the low degree of alloy purification due to the difficulty of controlling impurity gases [ 5 , 6 ]. In addition, solidification of conventional casting is slow, and segregation of components can occur, eventually leading to poor mechanical properties [ 7 , 8 , 9 , 10 ].…”

Section: Introductionmentioning

confidence: 99%

A Comparison of the Microstructure, Mechanical Properties, and Corrosion Resistance of the K213 Superalloy after Conventional Casting and Selective Laser Melting

Wang

Sui

et al. 2023

Materials

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K213 superalloy was fabricated by conventional casting and selective laser melting (SLM). The microstructures of the two samples were examined, and the mechanical properties and corrosion resistance of these two kinds of K213 alloy were comparatively studied. The results show that segregation of Ti occurs at the grain boundaries of the as-cast alloy, resulting in the formation of MC carbide. Many microcracks were formed in the SLM sample. Premature fracture of the as-cast alloy is caused by the precipitation of the harmful phase (Ti, Mo, Nb)C (MC). The MC carbides and microcracks in the as-cast and SLM alloys, respectively, induce tensile fracture. In comparison, the strength of the SLM sample is greater, while the elongation of the as-cast sample is greater. The oxidation resistance of the SLM sample is better at a high temperature of 800 °C. This is due to the relatively uniform composition and microstructure of the SLM alloy. However, the corrosion rate of the SLM alloy is accelerated during the electrochemical immersion corrosion process due to the existence of microcracks.

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Identifying Critical Defect Sizes From Pore Clusters in Nickel-based Superalloys Using Automated Analysis and Casting Simulation

Bellomo

Öztürk

Günzel³

et al. 2023

Metall Mater Trans A

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Porosity can form during investment casting as a result of the solidification conditions. Significant porosity can result in agglomerations (pore clusters) which are a primary crack initiation source and can result in reduced fatigue life of Nickel-based superalloys. Such clusters of porosity are today conventionally measured using 2D micrographs. An approach to accurately predict and analyze casting porosity from 2D cuts while facing in reality a 3D shape problem is currently missing. In this work, an approach that combines automation and simulation to assess the representative pore dimension, their interconnectivity and the porosity position is presented. On a LPT blade made of IN100, the porosity percentage and Feret diameter have been measured in multiple cuts and the porosity was found to be in the range of 0.88 to 5.4 pct. From the same micrographs the critical defect sizes were estimated with an automated tool to be in the range of 200 to 1800 $$\mu$$ μ m. The simulated shrinkage porosity for the same part, was predicted to be in the range of 1.67 to 2.33 pct. This study shows that the scaling factor between the pore Feret diameter and the critical pore size is equal to 2.9, in accordance to the proportionality of critical pores size clusters calculated from a 2D and 3D dataset. Finally, the simulated casting porosity was compared to that measured on cast blades in critical regions and the predictive accuracy is discussed in detail.

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Fatigue life assessment of a porous casting nickel-based superalloy based on fracture mechanics methodology

Cited by 15 publications

References 44 publications

Recent Advancements in the Field of Ni‐Based Superalloys

Recent Advancements in the Field of Ni‐Based Superalloys

A Comparison of the Microstructure, Mechanical Properties, and Corrosion Resistance of the K213 Superalloy after Conventional Casting and Selective Laser Melting

Identifying Critical Defect Sizes From Pore Clusters in Nickel-based Superalloys Using Automated Analysis and Casting Simulation

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