A cyclic slip irreversibility based model for fatigue crack initiation of nickel base alloys

The opportunity to define a microscopic law of fatigue crack initiation using Manson-Coffin law formulated in terms of cyclic slip irreversibility deduced from AFM measurements is discussed for a polycrystalline superalloy with different grain sizes and precipitate sizes. The results show that the modified Manson-Coffin law, relating cyclic slip irreversibility parameter to fatigue crack initiation life, is sustained through a two-parameter power law: ε′f and c. The analysis suggests that the exponent c-value can be related to the degree of plastic strain incompatibility between grains, and the cumulative irreversible cyclic plastic strain to crack initiation is a relevant damage indicator for crack initiation. Consequently, our approach allows giving a physical base of engineering law.

Surface Relief Formation in Relation to the Underlying Dislocation Arrangement

Two fatigued materials with f.c.c. lattice, i.e. pure polycrystalline copper and austenitic Sanicro 25 stainless steel, were subjected to the study of the persistent slip markings (PSMs) developed on the surface of the suitably oriented grains. They were observed using scanning electron microscopy (SEM) and thin surface FIB lamellae were prepared and studied by transmission electron microscopy (TEM). The aim was to correlate the specimen surface profile with the underlying internal dislocation structure. The localization of the intensive cyclic slip into persistent slip bands (PSBs) of the material was observed and associated with the PSMs on the specimen surface. Extrusions, intrusions and the dislocation structure appertaining to them were analysed, documented and discussed in relation to the models of fatigue crack initiation.

Cyclic Slip Localization and Crack Initiation in Crystalline Materials

Cyclic plastic straining in crystalline materials is localized to persistent slip bands (PSBs) and results in formation of persistent slip markings (PSMs) consisting of extrusions and intrusions. Intensive plastic strain in PSBs results in dislocation interactions and formation of point defects. The extended model based on point defect formation, migration and annihilation is presented describing surface relief formation in the form of extrusion-intrusion pairs. Point defect migration and resulting mass transfer is the principle source of cyclic slip irreversibility leading to crack-like defects - intrusions. Fatigue cracks start in the tip of sharp intrusions.

Experimental Evaluation of the Cyclic Slip Irreversibility Factor

Cyclic slip irreversibility is one of the most important features of fatigue processes in ductile metals because it induces surface relief evolutions during cycling which are mainly responsible for crack initiation. The reversible and irreversible parts of the slip within persistent slip bands (PSBs) in polycrystalline nickel are measured directly after half-cycle deformation and one full cycle on specimen surfaces once more well-polished after 60% of fatigue life using atomic force microscopy (AFM) and different techniques of scanning electron microscopy as electron channelling contrast imaging and electron backscattered diffraction. Using AFM measures on the same slip steps after half-cycle and full cycle, the cyclic slip irreversibility factor is directly evaluated and discussed with respect to the literature.