增材制造及固溶时效处理Inconel 718疲劳性能与寿命预测

孙传文; 孙锐; 李伟

doi:10.13224/j.cnki.jasp.20240570

增材制造及固溶时效处理Inconel 718疲劳性能与寿命预测

doi: 10.13224/j.cnki.jasp.20240570

孙传文^1,,
孙锐²,
李伟^1,*, ,

1.
北京理工大学机械与车辆学院，北京 100083
2.
西北有色金属研究院难熔金属材料研究所，西安 710016

基金项目: 国家自然科学基金（52175128）；西安交通大学金属材料强度国家重点实验室（20232501）

详细信息

作者简介:
孙传文（1997-），男，博士生，主要研究方向为增材制造航空航天材料超高周疲劳。E-mail：3220225082@bit.edu.cn

通讯作者:
李伟（1979-），男，副教授、博士生导师，博士，主要研究方向为增材制造航空航天结构疲劳、损伤及断裂。E-mail：lliw@bit.edu.cn

中图分类号: V252.2
计量
- 文章访问数: 906
- HTML浏览量: 487
- PDF量: 75
- 被引次数: 0
出版历程
- 收稿日期: 2024-08-16
- 网络出版日期: 2025-05-15

Fatigue properties and life prediction of additive manufacturing and solution aging Inconel 718

SUN Chuanwen^1
,,
SUN Rui²,
LI Wei^{1,*
, ,}

1.
School of Mechanical Engineering，Beijing Institute of Technology，Beijing 100083，China
2.
Refractory Materials Research Central，Northwest Institute for Non-Ferrous Metal Research，Xi’an 710016，China

摘要

摘要:
为了研究增材制造和经过航空领域标准热处理的镍基合金的疲劳性能，对沉积态和固溶时效试样开展了微观结构测试、拉伸试验和应力比R=−1和0.1的高周和超高周疲劳试验。试验结果表明：增材制造镍基合金经过固溶时效处理后，其拉伸和疲劳性能得以显著提升。表面失效是增材制造镍基合金在常温下的主要疲劳失效模式，但在R=0.1的长寿命状态下，裂纹萌生位置将会由材料表面向内部转移。拉伸和疲劳性能的提升主要归因于γ′、γ″和δ相的析出。在强化相的协同作用下，基体强度显著增加，位错移动受到抑制，裂纹扩展也被阻碍。缺陷和晶粒局部取向不相容都会导致内部裂纹的萌生。内部失效裂纹萌生区的微裂纹在剪切力作用下在以穿晶的形式扩展，晶粒断裂形成小平面。根据自应变能理论，建立了一种疲劳寿命预测方法，预测结果与试验结果具有较好的一致性。
- 增材制造 /
- 激光粉末床熔融 /
- 镍基合金 /
- 热处理 /
- 微观结构 /
- 超高周疲劳 /
- 疲劳失效机制 /
- 寿命预测
Abstract:
To investigate the fatigue properties of nickel-based alloy fabricated by additive manufacturing and heat treatment as standard in the aerospace field, the microstructural tests, tensile tests, and high-cycle and very high-cycle fatigue tests at stress ratios R=−1 and 0.1 were carried out on as-built and solution aging specimens. The test results showed that the tensile and fatigue properties of the additive manufactured nickel-based alloy were significantly improved after solution aging treatment. Surface failure was the main fatigue failure mode of additive manufactured nickel-based alloy at room temperature. The location of crack nucleation could be shifted from the surface of the material to the interior at the long-life regime of R=0.1. The improvement of tensile and fatigue properties was mainly attributed to the precipitation of γ′, γ″ and δ phases. Under the synergistic effects of these strengthening phases, the matrix was significantly strengthened, dislocation movement was inhibited and crack growth was hindered. Defects and incompatible local grain orientation can lead to internal crack nucleation. Microcracks in the internal crack nucleation area propagated under shear force in a grain transgranular manner, and the grains fracked to form facets. Based on the self-strain energy theory, a life prediction method was proposed, and the prediction results were in good agreement with the test results.
- additive manufacturing /
- laser powder bed fusion /
- nickel-based alloy /
- heat treatment /
- microstructure /
- very high cycle fatigue /
- fatigue failure mechanism /
- life prediction

HTML

图 1 LPBF镍基合金粉末

Figure 1. LPBF nickel-based alloy powder

下载: 全尺寸图片幻灯片

图 2 粉末尺寸分布

Figure 2. Size distribution of powder

下载: 全尺寸图片幻灯片

图 3 拉伸和疲劳试样的形状和尺寸（单位：mm）

Figure 3. Shape and size of tensile and fatigue specimens （unit：mm）

下载: 全尺寸图片幻灯片

图 4 SEM下的微观结构特征

Figure 4. Microstructure characteristics under SEM

下载: 全尺寸图片幻灯片

图 5 XRD图谱

Figure 5. XRD patterns

下载: 全尺寸图片幻灯片

图 6 EBSD下的晶粒形貌与显微织构

Figure 6. Grain morphology and microtexture under EBSD

下载: 全尺寸图片幻灯片

图 7 应力-应变曲线与硬度测试

Figure 7. Stress-strain curves and hardness tests

下载: 全尺寸图片幻灯片

图 8 SEM下的拉伸断口形貌

Figure 8. Tensile fractures under SEM

下载: 全尺寸图片幻灯片

图 9 S-N曲线

Figure 9. S-N curves

下载: 全尺寸图片幻灯片

图 10 沉积态和固溶时效试样在R=−1下的表面失效断口

Figure 10. Surface failure fractures of as-bulit and solution aging specimens at R=−1

下载: 全尺寸图片幻灯片

图 11 沉积态试样在R=0.1下的表面和次表面失效断口

Figure 11. Surface and subsurface failure fractures of as-bulit specimens at R=0.1

下载: 全尺寸图片幻灯片

图 12 固溶失效试样在R=0.1下表面和次表面失效断口

Figure 12. Surface and subsurface failure fractures of solution aging specimens at R=0.1

下载: 全尺寸图片幻灯片

图 13 次表面失效断口EBSD分析

Figure 13. EBSD analysis of subsurface failure fracture

下载: 全尺寸图片幻灯片

图 14 LPBF镍基合金裂纹萌生寿命预测结果

Figure 14. LPBF nickel-based alloy crack nucleation life prediction results

下载: 全尺寸图片幻灯片

图 15 预测结果与试验结果的对比

Figure 15. Comparison of the predicted and test results

下载: 全尺寸图片幻灯片

表 1 LPBF主要加工参数

Table 1. Main parameters of LPBF process

激光功率/W	扫描速度/（mm/s）	扫描间距/μm	层厚/μm
280	960	110	40

下载: 导出CSV

表 2 沉积态和固溶时效试样拉伸性能

Table 2. Tensile properties as-built and solution aging specimens

试样状态	屈服强度/MPa	抗拉强度/MPa	断后延伸率/%	弹性模量/GPa
沉积态	809	1035	34.5	165.35
固溶时效	1345	1430	16.0	179.92

下载: 导出CSV

表 3 沉积态试样在R=−1和0.1下的疲劳寿命

Table 3. Fatigue life of as-built specimens at R=−1 and 0.1

应力比	编号	最大应力幅值/MPa	疲劳寿命/ 10⁵周次	失效模式
−1	1	550	3.522	表面失效
	2	500	4.318	表面失效
	3	450	202.4	表面失效
	4	400	13.44	表面失效
	5	400	272.8	表面失效
	6	350	5065	表面失效
0.1	1	850	0.6650	表面失效
	2	750	3.463	表面失效
	3	700	30.54	表面失效
	4	650	71.65	表面失效
	5	600	1086	次表面失效
	6	550	831.9	表面失效

下载: 导出CSV

表 4 固溶时效试样在R=−1和0.1下的疲劳寿命

Table 4. Fatigue life of solution aging specimens at R=−1 and 0.1

应力比	编号	最大应力幅值/MPa	疲劳寿命/ 10⁵周次	失效模式
−1	1	650	0.5860	表面失效
	2	600	4.600	表面失效
	3	550	5.324	表面失效
	4	500	16.25	表面失效
	5	450	585.7	表面失效
	6	400	4680	表面失效
0.1	1	800	1.704	表面失效
	2	750	12.46	表面失效
	3	700	58.50	表面失效
	4	650	68.95	次表面失效
	5	600	2275	次表面失效

下载: 导出CSV

参考文献(28)

[1]	张小伟. 金属增材制造技术在航空发动机领域的应用[J]. 航空动力学报, 2016, 31(1): 10-16. ZHANG Xiaowei. Application of metal additive manufacturing in aero-engine[J]. Journal of Aerospace Power, 2016, 31(1): 10-16. (in Chinese ZHANG Xiaowei. Application of metal additive manufacturing in aero-engine[J]. Journal of Aerospace Power, 2016, 31(1): 10-16. (in Chinese)
[2]	ORMASTRONI L M B, LOPEZ-GALILEA I, PISTOR J, et al. Very high cycle fatigue durability of an additively manufactured single-crystal Ni-based superalloy[J]. Additive Manufacturing, 2022, 54: 102759. doi: 10.1016/j.addma.2022.102759
[3]	祝国梁, 罗桦, 贺戬, 等. 镍基高温合金增材制造研究进展[J]. 材料工程, 2024, 52(2): 1-15. ZHU Guoliang, LUO Hua, HE Jian, et al. Advances in additive manufacturing of nickel-based high-temperature alloys[J]. Journal of Materials Engineering, 2024, 52(2): 1-15. (in Chinese doi: 10.11868/j.issn.1001-4381.2023.000676 ZHU Guoliang, LUO Hua, HE Jian, et al. Advances in additive manufacturing of nickel-based high-temperature alloys[J]. Journal of Materials Engineering, 2024, 52(2): 1-15. (in Chinese) doi: 10.11868/j.issn.1001-4381.2023.000676
[4]	隋天校, 石多奇, 王相平, 等. 取向相关的单晶高温合金低周疲劳寿命评估方法[J]. 航空动力学报, 2021, 36(10): 2139-2148. SUI Tianxiao, SHI Duoqi, WANG Xiangping, et al. Orientation-dependent low-cycle fatigue life evaluation method for single crystal superalloys[J]. Journal of Aerospace Power, 2021, 36(10): 2139-2148. (in Chinese SUI Tianxiao, SHI Duoqi, WANG Xiangping, et al. Orientation-dependent low-cycle fatigue life evaluation method for single crystal superalloys[J]. Journal of Aerospace Power, 2021, 36(10): 2139-2148. (in Chinese)
[5]	袁战伟, 常逢春, 马瑞, 等. 增材制造镍基高温合金研究进展[J]. 材料导报, 2022, 36(3): 206-214. YUAN Zhanwei, CHANG Fengchun, MA Rui, et al. Research progress of additive manufacturing of nickel-based superalloys[J]. Materials Reports, 2022, 36(3): 206-214. (in Chinese YUAN Zhanwei, CHANG Fengchun, MA Rui, et al. Research progress of additive manufacturing of nickel-based superalloys[J]. Materials Reports, 2022, 36(3): 206-214. (in Chinese)
[6]	MOSTAFAEI A, GHIAASIAAN R, HO I T, et al. Additive manufacturing of nickel-based superalloys: a state-of-the-art review on process-structure-defect-property relationship[J]. Progress in Materials Science, 2023, 136: 101108. doi: 10.1016/j.pmatsci.2023.101108
[7]	CHOUDHARY S, PANDEY A, GAUR V. Role of microstructural phases in enhanced mechanical properties of additively manufactured IN718 alloy[J]. Materials Science and Engineering: A, 2023, 862: 144484. doi: 10.1016/j.msea.2022.144484
[8]	ZHAO Yanan, GUO Qianying, LI Chong, et al. Achieving superior elevated temperature properties in additive manufactured nickel-based superalloys through unique alloy design[J]. Additive Manufacturing, 2024, 88: 104273. doi: 10.1016/j.addma.2024.104273
[9]	SADEGHI E, KARIMI P, ESMAEILIZADEH R, et al. A state-of-the-art review on fatigue performance of powder bed fusion-built alloy 718[J]. Progress in Materials Science, 2023, 133: 101066. doi: 10.1016/j.pmatsci.2022.101066
[10]	LI Wei, SUN Rui, HU Tianyi, et al. Effect of elevated temperature on high-cycle and very-high-cycle fatigue properties of Ni-based superalloy manufactured by selective laser melting[J]. International Journal of Fatigue, 2021, 148: 106250. doi: 10.1016/j.ijfatigue.2021.106250
[11]	胡殿印, 潘锦超, 米栋, 等. 航空发动机增材制造结构强度、寿命评估与设计: 研究现状及展望[J]. 航空动力学报, 2022, 37(10): 2112-2126. HU Dianyin, PAN Jinchao, MI Dong, et al. Strength and lifetime assessment and design for additive manufacturing structures in aero-engine: review and prospects[J]. Journal of Aerospace Power, 2022, 37(10): 2112-2126. (in Chinese HU Dianyin, PAN Jinchao, MI Dong, et al. Strength and lifetime assessment and design for additive manufacturing structures in aero-engine: review and prospects[J]. Journal of Aerospace Power, 2022, 37(10): 2112-2126. (in Chinese)
[12]	吴圣川, 胡雅楠, 杨冰, 等. 增材制造材料缺陷表征及结构完整性评定方法研究综述[J]. 机械工程学报, 2021, 57(22): 3-34. WU Shengchuan, HU Yanan, YANG Bing, et al. Review on defect characterization and structural integrity assessment method of additively manufactured materials[J]. Journal of Mechanical Engineering, 2021, 57(22): 3-34. (in Chinese doi: 10.3901/JME.2021.22.003 WU Shengchuan, HU Yanan, YANG Bing, et al. Review on defect characterization and structural integrity assessment method of additively manufactured materials[J]. Journal of Mechanical Engineering, 2021, 57(22): 3-34. (in Chinese) doi: 10.3901/JME.2021.22.003
[13]	NIU Xiaopeng, HE Chao, ZHU Shunpeng, et al. Defect sensitivity and fatigue design: deterministic and probabilistic aspects in additively manufactured metallic materials[J]. Progress in Materials Science, 2024, 144: 101290. doi: 10.1016/j.pmatsci.2024.101290
[14]	YU Chuanli, HUANG Zhiyong, ZHANG Zian, et al. Influence of post-processing on very high cycle fatigue resistance of Inconel 718 obtained with laser powder bed fusion[J]. International Journal of Fatigue, 2021, 153: 106510. doi: 10.1016/j.ijfatigue.2021.106510
[15]	王冠, 宋巍, 梁静静, 等. 热处理对一种新型增材制造镍基高温合金显微组织与拉伸性能的影响[J]. 稀有金属材料与工程, 2024, 53(3): 787-795. WANG Guan, SONG Wei, LIANG Jingjing, et al. Effect of heat treatment on microstructure and tensile properties of a new type of Ni-based superalloy designed for additive manufacturing[J]. Rare Metal Materials and Engineering, 2024, 53(3): 787-795. (in Chinese doi: 10.12442/j.issn.1002-185X.20230109 WANG Guan, SONG Wei, LIANG Jingjing, et al. Effect of heat treatment on microstructure and tensile properties of a new type of Ni-based superalloy designed for additive manufacturing[J]. Rare Metal Materials and Engineering, 2024, 53(3): 787-795. (in Chinese) doi: 10.12442/j.issn.1002-185X.20230109
[16]	高天明, 程晓农, 罗锐, 等. 时效处理对GH4169合金显微组织及高温拉伸变形行为的影响[J]. 金属热处理, 2020, 45(8): 119-123. GAO Tianming, CHENG Xiaonong, LUO Rui, et al. Effect of aging treatment on microstructure and high temperature tensile deformation behavior of GH4169 alloy[J]. Heat Treatment of Metals, 2020, 45(8): 119-123. (in Chinese GAO Tianming, CHENG Xiaonong, LUO Rui, et al. Effect of aging treatment on microstructure and high temperature tensile deformation behavior of GH4169 alloy[J]. Heat Treatment of Metals, 2020, 45(8): 119-123. (in Chinese)
[17]	CAO G H, SUN T Y, WANG C H, et al. Investigations of γ′, γ″ and δ precipitates in heat-treated inconel 718 alloy fabricated by selective laser melting[J]. Materials Characterization, 2018, 136: 398-406. doi: 10.1016/j.matchar.2018.01.006
[18]	ZHANG Yiting, LAN Liangyun, ZHAO Yang. Effect of precipitated phases on the mechanical properties and fracture mechanisms of Inconel 718 alloy[J]. Materials Science and Engineering: A, 2023, 864: 144598. doi: 10.1016/j.msea.2023.144598
[19]	XI Naiyuan, NI Zhiyang, FANG Xuewei, et al. Role of δ-phase on mechanical behaviors of additive manufactured Inconel 718: detailed microstructure analysis and crystal plasticity modelling[J]. International Journal of Plasticity, 2023, 168: 103708. doi: 10.1016/j.ijplas.2023.103708
[20]	WAN Hongyuan, ZHOU Zhongjiao, LI Changpeng, et al. Enhancing fatigue strength of selective laser melting-fabricated Inconel 718 by tailoring heat treatment route[J]. Advanced Engineering Materials, 2018, 20(10): 1800307. doi: 10.1002/adem.201800307
[21]	BARTLETT J L, LI Xiaodong. An overview of residual stresses in metal powder bed fusion[J]. Additive Manufacturing, 2019, 27: 131-149. doi: 10.1016/j.addma.2019.02.020
[22]	HARTE A, ATKINSON M, PREUSS M, et al. A statistical study of the relationship between plastic strain and lattice misorientation on the surface of a deformed Ni-based superalloy[J]. Acta Materialia, 2020, 195: 555-570. doi: 10.1016/j.actamat.2020.05.029
[23]	ZHENG H, PENG J F, SUN X, et al. Distribution of microstructure, elastic modulus and residual stress near the interface in laser repaired GH4169 superalloy[J]. Journal of Alloys and Compounds, 2023, 966: 171625. doi: 10.1016/j.jallcom.2023.171625
[24]	LALEH M, SADEGHI E, REVILLA R I, et al. Heat treatment for metal additive manufacturing[J]. Progress in Materials Science, 2023, 133: 101051. doi: 10.1016/j.pmatsci.2022.101051
[25]	XU K, JIANG H, YAN J B, et al. Tensile properties and deformation mechanisms of a solution treated Ni–Fe-based alloy at high temperatures[J]. Materials Science and Engineering: A, 2023, 881: 145418. doi: 10.1016/j.msea.2023.145418
[26]	ZHAO Zhenan, YANG Weizhu, LI Lei, et al. Improved high-temperature fatigue performance of laser directed energy deposited Ni-based superalloy by regulating the heat treatment[J]. International Journal of Fatigue, 2023, 169: 107463. doi: 10.1016/j.ijfatigue.2022.107463
[27]	TANAKA K, MURA T. A theory of fatigue crack initiation at inclusions[J]. Metallurgical Transactions A, 1982, 13(1): 117-123. doi: 10.1007/BF02642422
[28]	LI Xiaolong, ZHANG Yucheng, LI Wei, et al. High-cycle and very-high-cycle fatigue behavior and life prediction of Ni-based superalloy at elevated temperature[J]. Fatigue & Fracture of Engineering Materials & Structures, 2021, 44(12): 3431-3447.