Surface integrity and fatigue failure behavior of nickel based alloy blades: After cutting, vibration finishing and shot peening

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL Engineering Failure Analysis Pub Date : 2024-11-01 DOI:10.1016/j.engfailanal.2024.109034

Yunqi Sun , Changfeng Yao , Liang Tan , Minchao Cui , Tao Fan , Yilong Cao , Yaoguo Ma

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Abstract

This article selected three processes to prepare nickel based alloy GH4169G blades, tested the surface integrity changes of different processes, conducted high cycle vibration fatigue tests, and studied their failure mechanisms. The results indicate that the milling polishing vibration precision machining (MV) process can effectively reduce the surface roughness of milling (M) process blades, while the milling polishing vibration precision machining shot peening (MVSP) process significantly improves the residual compressive stress and hardening layer level of blades. The MVSP process blades have the best vibration fatigue life, with an average life of 4.91 × 10⁶, which is 775.2 % higher than the M process blades. The fatigue life of the blades has been significantly improved. After MV process treatment, the blade undergoes a transition from multi-source fatigue caused by M process to surface single source fatigue crack initiation. The crack initiation location of MVSP process blades shifted from the surface to about 0.097 mm below the surface, and shot peening significantly improved the fatigue crack initiation life of the blades.

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镍基合金刀片的表面完整性和疲劳失效行为：切削、振动精加工和喷丸强化后

本文选取了制备镍基合金 GH4169G 刀片的三种工艺，测试了不同工艺的表面完整性变化，进行了高循环振动疲劳试验，并研究了其失效机理。结果表明，铣削抛光振动精密加工（MV）工艺能有效降低铣削（M）工艺叶片的表面粗糙度，而铣削抛光振动精密加工喷丸强化（MVSP）工艺能显著提高叶片的残余压应力和硬化层水平。MVSP 工艺叶片的振动疲劳寿命最好，平均寿命为 4.91 × 106，比 M 工艺叶片高出 775.2%。叶片的疲劳寿命得到了显著提高。经过 MV 工艺处理后，叶片从 M 工艺引起的多源疲劳过渡到表面单源疲劳裂纹起始。MVSP 工艺叶片的裂纹起始位置从表面转移到表面以下约 0.097 mm 处，喷丸处理显著提高了叶片的疲劳裂纹起始寿命。

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.