Abstract
The high- and very-high-cycle-fatigue properties of IN718 Ni-based superalloy manufactured by selective laser melting (SLM) were investigated by axially loaded fatigue tests at room temperature (25 °C) and elevated temperature (650 °C) with a stress ratio of R = −1. Due to the high energy density and rapid cooling rate of the SLM process, the grains grew as dendrites surrounded by chain and dotted Laves phases. Subsequently, the results of monotonic tensile tests show that the SLMed IN718 has good resistance to elevated temperature. The stress–life characteristic curves revealed a continuous decline with no conventional fatigue limit. The fracture observation illustrated that surface flaw-induced failure is predominant at 25 °C, while internal failure, caused by crystallographic facets cracking, is prevalent at 650 °C under lower stress. Furthermore, the internal failure mechanism related with microstructure was summarized. Based on the evaluation of stress intensity factor ranges, the threshold values of long and small crack growth can be obtained, as well as the transition lengths from small to long cracks can also be calculated. Finally, a model based on fatigue indicator parameter was proposed to predict the fatigue life, and the predicted results were acceptable.
Similar content being viewed by others
References
X.F. Ding, Q. Feng, Y.R. Zheng, and X.F. Ding, Formation of Hole-Edge Cracks in a Combustor Liner of an Aero Engine, Eng. Fail. Anal., 2015, 55, p 148–156.
T.D. Ngo, A. Kashani, G. Imbalzano, K. Nguyen, and D. Hui, Additive Manufacturing (3D Printing): A Review of Materials, Methods, Appl. Chall. Compos. Part B Eng., 2018, 143, p 172–196.
E. Hosseini and V.A. Popovich, A Review of Mechanical Properties of Additively Manufactured Inconel 718, Addit. Manuf., 2019, 30, p 100877.
D.S. Watring, J.T. Benzing, N. Hrabe, and A.D. Spear, Effects of Laser-Energy Density and Build Orientation on the Structure-Property Relationships in as-Built Inconel 718 Manufactured by Laser Powder Bed Fusion, Addit. Manuf., 2020, 36, p 101425.
G.C. Huang, G.Q. Liu, M.N. Feng, M. Zhang, B.F. Hu, and H. Wang, The Effect of Cooling Rates from Temperatures Above the γ’ Solvus on the Microstructure of a New Nickel-Based Powder Metallurgy superalloy, J. Alloy Compd., 2018, 747, p 1062–1072.
A. Yadollahi, N. Shamsaei, S.M. Thompson, and D. Seely, Effects of Process Time Interval and Heat Treatment on the Mechanical and Microstructural Properties of Direct Laser Deposited 316L Stainless Steel, Mater. Sci. Eng. A, 2015, 644, p 171–183.
T.M. Smith, T.P. Gabb, C.A. Kantzos, A.C. Thompson, C.K. Sudbrack, B. West, D.L. Ellis, and C.L. Bowman, The Effect of Composition on Microstructure and Properties for Additively Manufactured Superalloy 718, J. Alloy Compd., 2021, 873, p 159789.
M. Mahmoudi, A. Elwany, A. Yadollahi, S. Thompson, L. Bian, and N. Shamsaei, Mechanical Properties and Microstructural Characterization of Selective Laser Melted 17-4 PH Stainless Steel, Rapid Prototyp. J., 2017, 23, p 280–294.
Y.C. Wang, J. Shi, and Y. Liu, Competitive Grain Growth and Dendrite Morphology Evolution in Selective Laser Melting of Inconel 718 Superalloy, J. Cryst. Growth, 2019, 521, p 15–29.
S. Sui, H. Tan, J. Chen, C.L. Zhong, Z. Li, W. Fan, A. Gasser, and W.D. Huang, The influence of Laves Phases on the Room Temperature Tensile Properties of Inconel 718 Fabricated by Powder Feeding Laser Additive Manufacturing, Acta Mater., 2019, 164, p 413–427.
Y.H. Liu, Y. Wu, J.W. Yu, J. Ju, Z. Zhang, M.D. Kang, J. Wang, B.D. Sun, and Y. Ning, Temperature-Dependent Deformation Mechanisms and Microstructural Degradation of a Polycrystalline Nickel-Based Superalloy, J. Alloy Compd., 2019, 775, p 181–192.
J.J. Xu, X. Lin, P.F. Guo, H.O. Yang, L. Xue, W.D. Huang, L. Xue, and W.D. Huang, The Microstructure Evolution and Strengthening Mechanism of a γ’-Strengthening Superalloy Prepared by Induction-Assisted Laser Solid Forming, J. Alloy Compd., 2019, 780, p 461–475.
S. Kumari, D.V.V. Satyanarayana, and M. Srinivas, Failure Analysis of Gas Turbine Rotor Blades, Eng. Fail. Anal., 2014, 45, p 234–244.
A. Burov and E. Fedorova, Modeling of Interface Failure in a Thermal Barrier Coating System on Ni-Based Superalloys, Eng. Fail. Anal., 2021, 123, p 105320.
D. Shi, Z. Cheng, Z. Li, X. Yang, and M. Wang, Viscoplastic Constitutive Model for Ni-Based Directionally Solidified Superalloy: Experimental Validation on Notched Specimen, Eng. Fail. Anal., 2020, 118, p 104930.
Y.L. Hu, X. Liu, Y.L. Li, Y.C. Ou, X.H. Gao, Q. Zhang, W. Li, and W.D. Huang, Microstructural Evolution and Anisotropic Mechanical Properties of Inconel 625 Superalloy Fabricated by Directed Energy Deposition, J. Alloy Compd., 2021, 870, p 159426.
Z.H. Jiao, L.M. Lei, H.C. Yu, F. Xu, R.D. Xu, and X.R. Wu, Experimental Evaluation on Elevated Temperature Fatigue and Tensile Properties of one Selective Laser Melted Nickel Based Superalloy, Int. J. Fatigue, 2019, 121, p 172–180.
D. Pradhan, G.S. Mahobia, K. Chattopadhyay, and V. Singh, Effect of Pre Hot Corrosion on High Cycle Fatigue Behavior of the Superalloy IN718 at 600 °C, Int. J. Fatigue, 2018, 114, p 120–129.
P.D. Nezhadfar, A.S. Johnsonc, and N. Shamsaei, Fatigue Behavior and Microstructural Evolution of Additively Manufactured Inconel 718 under Cyclic Loading at Elevated Temperature, Int. J. Fatigue, 2020, 136, p 105598.
Y. Yamashita, T. Murakami, R. Miharaa, M. Okadab, and Y. Murakami, Defect Analysis and Fatigue Design Basis for Ni-Based Superalloy 718 Manufactured by Selective Laser Melting, Int. J. Fatigue, 2018, 117, p 485–495.
Z.W. Xu, A. Liu, and X.S. Wang, The Influence of Building Direction on the Fatigue Crack Propagation Behavior of Ti6Al4V Alloy Produced by Selective Laser Melting, Mater. Sci. Eng. A, 2019, 767, p 138409.
Z.W. Xu, A. Liu, and X.S. Wang, Fatigue Performance and Crack Propagation Behavior of Selective Laser Melted AlSi10Mg in 0°, 15°, 45° and 90° Building Directions, Int. J. Fatigue, 2021, 812, p 141141.
T. Murakami and Y. Murakami, Effects of Small Defects and Nonmetallic Inclusions on the Fatigue Strength of Metals, Key Eng. Mater., 1991, 51–52, p 37–42.
T. Sakai, A. Nakagawa, N. Oguma, Y. Nakamura, and A. Ueno, A Review on Fatigue Fracture Modes of Structural Metallic Materials in Very High Cycle Regime, Int. J. Fatigue, 2016, 93, p 339–351.
S. Shao, M.M. Khonsari, S. Guo, W.J. Meng, and N. Li, Overview: Additive Manufacturing Enabled Accelerated Design of Ni-Based Alloys for Improved Fatigue Life, Addit. Manuf., 2019, 29, p 100779.
J.S. Miao, T.M. Pollock, and J.W. Jones, Crystallographic Fatigue Crack Initiation in Nickel-Based Superalloy Rene′ 88DT at Elevated Temperature, Acta Mater., 2009, 57, p 5964–5974.
C. Stöcker, M. Zimmermannn, and H.J. Christ, Localized Cyclic Deformation and Corresponding Dislocation Arrangements of Polycrystalline Ni-Base Superalloys and Pure Nickel in the VHCF Regime, Int. J. Fatigue, 2011, 33, p 2–9.
A. Amanov, Y. Pyun, J. Kim, C. Suh, I. Cho, Q.Y. Wang, and M.K. Khan, Ultrasonic Fatigue Performance of High Temperature Structural Material Inconel 718 Alloys at High Temperature After UNSM Treatment, Fatigue Fract. Eng. Mater. Struct., 2015, 38, p 1266–1273.
S. Utada, L.M.B. Ormastroni, J. Rame, P. Villechaise, and J. Cormier, VHCF Life of AM1 Ni-Based Single Crystal Superalloy After Pre-deformation, Int. J. Fatigue, 2021, 148, p 106224.
K. Yang, Q. Huang, Q.Y. Wang, and Q. Chen, Competing Crack Initiation Behaviors of a Laser Additively Manufactured Nickel-Based Superalloy in High and Very High Cycle Fatigue Regimes, Int. J. Fatigue, 2020, 136, p 105580.
X.B. Yu, X. Lin, H. Tan, Y.L. Hu, S.Y. Zhang, F.C. Liu, H.O. Yang, and W.D. Huang, Microstructure and Fatigue Crack Growth Behavior of Inconel 718 Superalloy Manufactured by Laser Directed Energy Deposition, Int. J. Fatigue, 2021, 143, p 106005.
T.J. Zhou, H.S. Ding, X.P. Ma, W. Feng, H.B. Zhou, A.L. Li, Y. Meng, and H.X. Zhang, Effect of Precipitates on High-Temperature Tensile Strength of a High W-Content Cast Ni-Based Superalloy, J. Alloys Compd., 2019, 797, p 486–496.
W.G. Li, J.Z. Ma, H.B. Kou, J.X. Shao, X.Y. Zhang, Y. Deng, Y. Tao, and D.N. Fang, Modeling the Effect of Temperature on the Yield Strength of Precipitation Strengthening Ni-Base Superalloys, Int. J. Plast., 2019, 116, p 143–158.
S. Sui, J. Chen, E.X. Fan, H.O. Yang, X. Lin, and W.D. Huang, The Influence of Laves Phases on the High-Cycle Fatigue Behavior of Laser Additive Manufactured Inconel 718, Mater. Sci. Eng. A, 2017, 695, p 6–13.
X. Li, R.F. Zhang, X.Y. Wang, Y.J. Liu, C. Wang, H. Zhang, L. Li, C. He, and Q.Y. Wang, Effect of High Temperature on Crack Initiation of Super Austenitic Stainless Steel 654SMO in Very High Cycle Fatigue, Mater. Des., 2020, 193, p 108750.
X.B. Yu, X. Lin, H. Tan et al., Microstructure and Fatigue Crack Growth Behavior of Inconel 718 Superalloy Manufactured by Laser Directed Energy Deposition, Int. J. Fatigue, 2021, 143, p 106005.
J.C. Stinville, E. Martin, M. Karadge, S. Ismonov, M. Soare, T. Hanlon et al., Competing Modes for Crack Initiation from Nonmetallic Inclusions and Intrinsic Microstructural Features during Fatigue in a Polycrystalline Nickel-Based Superalloy, Metall. Mater. Trans. A, 2018, 49, p 3865–3873.
J.C. Stinville, E. Martin, M. Karadge, S. Ismonov, M. Soare, T. Hanlon et al., Fatigue Deformation in a Polycrystalline Nickel Base Superalloy at Intermediate and High Temperature: Competing Failure Modes, Acta Mater., 2018, 152, p 16–33.
W. Li, R. Sun, P. Wang, X.L. Li, Y.C. Zhang, T.Y. Hu, C. Li, and T. Sakai, Subsurface Faceted Cracking Behavior of Selective Laser Melting Ni-Based Superalloy under Very High Cycle Fatigue, Scr. Mater., 2021, 194, p 113613.
N. Kawagoishi, Q. Chen, and H. Nisitani, Fatigue Strength of Inconel 718 at Elevated Temperatures, Fatigue Fract. Eng. Mater. Struct., 2000, 23, p 209–216.
Y. Murakami, S. Kodama, and S. Konuma, Quantitative Evaluation of Effect of Nonmetallic Inclusions on Fatigue Strength of High Strength Steel, Trans. Jpn. Soc. Mech. Eng., 1988, 54, p 688–695.
G. Gao, Q. Xu, H. Guo, X. Gui, B. Zhang, and B. Bai, Effect of Inclusion and Microstructure on the Very High Cycle Fatigue Behavior of High Strength Bainite/Martensite Multiphase Steels, Mater. Sci. Eng. A, 2019, 739, p 404–414.
Y. Murakami and M. Endo, Effects of Defects, Inclusions and Inhomogeneities on Fatigue Strength, Int. J. Fatigue, 1994, 16, p 163–182.
D.B. Witkin, D. Patel, T.V. Albright, G.E. Bean, and T. McLouth, Influence of Surface Conditions and Specimen Orientation on High Cycle Fatigue Properties of Inconel 718 Prepared by Laser Powder Bed Fusion, Int. J. Fatigue, 2020, 132, p 105392.
Y. Murakami, Metal Fatigue Effects of Small Defects and Nonmetallic Inclusions, Elsevier Science, Amsterdam Boston, 2002.
Z.W. Xu, A. Liu, X.S. Wang, B. Liu, and M.H. Guo, Fatigue Limit Prediction Model and Fatigue Crack Growth Mechanism for Selective Laser Melting Ti6Al4V Samples with Inherent Defects, Int. J. Fatigue, 2021, 143, p 106008.
A. Fatemi and D.F. Socie, A Critical Plane Approach to Multiaxial Fatigue Damage Including Out-of-Phase Loading, Fatigue Eng. Mater., 1988, 11, p 149–165.
M.W. Brown and K.J. Miller, A Theory for Fatigue Failure under Multiaxial Stress and Strain Conditions, Proc. Inst. Mecha. Eng., 1973, 187, p 745–755.
A. Cervellon, J. Cormier, F. Mauget, and Z. Hervier, VHCF Life Evolution After Microstructure Degradation of a Ni-Based Single Crystal Superalloy, Int. J. Fatigue, 2017, 104, p 251–262.
A. Cervellon, S. Hemery, P. Kurnsteiner, B. Gault, P. Kontis, and J. Cormier, Crack Initiation Mechanisms During Very High Cycle Fatigue of Ni-Based Single Crystal Superalloys at High Temperature, Acta Mater., 2020, 188, p 131–144.
Acknowledgments
This work was supported by the Special Project for Seed-Innovation of NIN (grant number: ZZNR2202).
Author information
Authors and Affiliations
Contributions
RS was involved in data curation, methodology, writing—original draft; WZ helped in supervision, writing—review & editing, funding acquisition; HL and YZ contributed to investigation; MX was involved in visualization; RB helped in formal analysis; XC contributed to data curation; FW helped in validation.
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Sun, R., Zhang, W., Liu, H. et al. Very-High-Cycle-Fatigue Property of IN 718 Manufactured by Selective Laser Melting at Elevated Temperature: Microstructure-Related Failure Behavior and Life Prediction. J. of Materi Eng and Perform 33, 4377–4391 (2024). https://doi.org/10.1007/s11665-023-08327-0
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-023-08327-0