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Dong Sun, Siliang He, Longfei Li, Song Lu, Weiwei Zheng, Jonathan Cormier, and Qiang Feng, High-cycle fatigue life improvement of a PtAl-coated third-generation Ni-based single crystal superalloy after thermal exposure, Int. J. Miner. Metall. Mater., (2025). https://doi.org/10.1007/s12613-025-3157-z
Dong Sun, Siliang He, Longfei Li, Song Lu, Weiwei Zheng, Jonathan Cormier, and Qiang Feng, High-cycle fatigue life improvement of a PtAl-coated third-generation Ni-based single crystal superalloy after thermal exposure, Int. J. Miner. Metall. Mater., (2025). https://doi.org/10.1007/s12613-025-3157-z
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热暴露后含PtAl涂层第三代镍基单晶高温合金高周疲劳性能提升的影响机制研究

摘要: 涂层/互扩散区及互扩散区/单晶合金界面附近的显微组织对含沉积态涂层单晶高温合金高周疲劳(HCF)性能影响显著,且服役过程中上述显微组织不可避免地会发生退化,但显微组织退化对含涂层单晶高温合金HCF性能的影响尚不清楚。本文对比研究了沉积态及经1100°C不同时间热暴露后的含PtAl涂层第三代镍基单晶高温合金薄板试样在900°C下的HCF行为,通过分析表面微裂纹及其附近显微组织的演变行为,阐明了热暴露过程中涂层与单晶合金间元素互扩散和显微组织演变对HCF行为的影响机制。结果表明,对比含沉积态涂层单晶高温合金,经热暴露后的含涂层单晶高温合金疲劳裂纹源均由表面裂纹转变为内部孔洞,导致HCF性能明显提升。HCF过程中,相较含沉积态涂层单晶高温合金,经热暴露后的含涂层单晶合金表面微裂纹在涂层和互扩散区(IDZ)内依然沿晶界萌生和扩展,但微裂纹在近IDZ单晶合金中扩展受阻,使疲劳裂纹源发生转变。含沉积态涂层单晶高温合金表面微裂纹尖端易形成疏松易开裂的氧化产物,促进微裂纹扩展。相比之下,热暴露后的含涂层单晶高温合金近IDZ单晶合金中Pt和Al元素含量增加,促进微裂纹尖端形成具有保护作用的Al2O3,延缓了表面微裂纹向基体内的扩展;近IDZ单晶合金P型筏排组织的形成进一步阻碍了微裂纹的扩展。本研究为预测含涂层单晶高温合金的HCF性能提供了数据基础。

 

High-cycle fatigue life improvement of a PtAl-coated third-generation Ni-based single crystal superalloy after thermal exposure

Abstract: The as-deposited coating–substrate microstructure has been identified to substantially influence the high-cycle fatigue (HCF) behavior of Ni-based single-crystal (SX) superalloys at 900°C, but the impact of degraded microstructure on the HCF behavior remains unclear. In this work, a PtAl-coated third-generation SX superalloy with sheet specimen was thermal-exposed at 1100°C with different durations and then subjected to HCF tests at 900°C. The influence of microstructural degradation on the HCF life and crack initiation were clarified by analyzing the development of microcracks and coating–substrate microstructure. Notably, the HCF life of the thermal-exposed coated alloy increased abnormally, which was attributed to the transformation of the fatigue crack initiation site from surface microcracks to internal micropores compared to the as-deposited coated alloy. Although the nucleation and growth of surface microcracks occurred along the grain boundaries in the coating and the interdiffusion zone (IDZ) for both the as-deposited and the thermal-exposed coated alloys, remarkable differences of the microcrack growth into the substrate adjacent to the IDZ were observed, changing the crack initiation site. Specifically, the surface microcracks grew into the substrate through the cracking of the non-protective oxide layers in the as-deposited coated alloy. In comparison, the hinderance of the surface microcracks growth was found in the thermal-exposed coated alloy, due to the formation of a protective Al2O3 layer within the microcrack and the γ′ rafting in the substrate close to the IDZ. This study will aid in improving the HCF life prediction model for the coated SX superalloys.

 

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