Comparison of wrought and additively manufactured IN718 concerning crack growth threshold and fatigue crack growth behaviour

Rotary components in turbine machinery such as gas turbine blades and discs or turbocharger wheels need to be designed so that high cycle fatigue (HCF) loads are well below the fatigue endurance limit to ensure safe operation. This requires an accurate measurement of the fatigue endurance limit and the related intrinsic fatigue crack growth (FCG) threshold. Furthermore, knowing the FCG threshold is crucial in order to assess the criticality of initial defects (e.g. cavities, carbide nests, etc.). In this study, the influence of the manufacturing route on the FCG threshold and the FCG behaviour at 650 °C in air of the nickel based superalloy IN718 is investigated. For this, a per Laser Powder Bed Fusion (LPBF) process manufactured version is compared to a conventionally wrought IN718 material state, both in the short and long crack regime. To measure crack growth increments of about 1 μm, an alternative pre-cracking and threshold test procedure is proposed for high temperature testing. To assess the behaviour of both material states in the short crack growth regime, cyclic R-curves have been generated taking the influence of two different R ratios into account. A further comparison of the FCG behaviour of the LPBF and the wrought material state is made on the basis of da/dN-ΔKI plots, with a focus on the Paris regime created from both classical FCG tests as well as continued threshold tests. The results observed are discussed in relation to the initial characterization of the two material states, which includes tensile tests at room temperature and at 650 °C as well as microstructural investigations.