MCrAlY涂覆的镍基高温合金及其基体合金的等温和热机械疲劳行为
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摘要
镍基高温合金具有较高的高温屈服强度和蠕变强度,以及良好的抗热腐蚀和抗氧化性能,因此被广泛应用于制作涡轮叶片和导向叶片,以及其它高温结构部件。绝大多数的高温结构部件在服役条件下都承受着热机械疲劳(TMF)载荷,研究表明,材料的热机械疲劳寿命比在热机械疲劳循环最高温度下的等温低周疲劳(IF)寿命低。热机械疲劳试验是在实验室中最能够模拟高温部件服役状态的方法,因此对材料在TMF试验条件下的损伤和失效机制的研究是十分重要的,这将为高温结构部件的疲劳设计和寿命预测提供可靠的理论依据。
本文研究了两种铸造镍基高温合金M38和M963在900℃下的低周疲劳行为,并对M963进行了450-900℃的热机械疲劳行为研究和寿命预测研究。结果表明,M38和M963在900℃下均表现出了良好稳定的低周疲劳性能。将M38与M963在900℃的抗氧化性能、强度和延性加以对比发现,M963具有与M38接近的抗氧化性能,可以接受的延性,以及较为突出的高温强度,适合用来进行条件更为苛刻的热机械疲劳试验。
对M963合金的同相位(IP)和反相位(OP)热机械疲劳研究表明,与同应变速率下的900℃IF相比较,IP和OP TMF总是具有较低的寿命。这是由于热机械疲劳高温半周和低温半周不同形变机制的交互作用导致了热机械疲劳损伤较大的原因。此外,IPTMF和OP TMF的机械应变—疲劳寿命曲线有轻微的交叉现象,当机械应变幅较大时,IP TMF的寿命较低,这是因为在较高的机械应变幅下发生了蠕变损伤;而当机械应变幅较小时,OP TMF的寿命较低,这被认为是OP TMF时的拉伸平均应力以及氧化与疲劳的交互作用发生综合损伤的结果。对断口和剖面分析表明,IP TMF试验条件下,当机械应变幅较大时,疲劳裂纹沿晶萌生,而当机械应变幅较小时,裂纹倾向于在枝晶间萌生;OP TMF试验条件下,所有应变幅时疲劳裂纹都穿晶萌生。
对用等温疲劳数据预测热机械疲劳寿命的研究表明,Zamrik模型和Miller模型能够很好地使用等温疲劳数据预测热机械疲劳寿命,这是因为其损伤参量综合考虑了塑性应变和弹性应变;而只考虑塑性应变的Ostergren模型不能够用等温疲劳数据预测热机械疲劳寿命。本文提出了一种热机械疲劳总能量损伤寿命预测模型,此模型很好地解决了高强度低韧性镍基高温合金热机械疲劳条件下塑性应变幅过低导致无法用其进行寿命预测的问题。
由于实际服役条件下热端部件表面经常涂覆MCrAlY防护涂层和陶瓷热障涂层,因此研究MCrAlY涂层对材料疲劳性能的影响十分重要。本文研究了分别涂覆大气等离子喷涂(APS)和高速氧火焰喷涂(HVOF)MCrAlY涂层的M963合金在900℃等温疲劳及450-900℃热机械疲劳条件下的开裂机制以及涂层对M963合金失效机制和疲劳寿命的影响。
对涂覆MCrAlY涂层的M963合金在900℃IF以及IP和OP TMF试验条件下的失效机制和寿命的研究表明,在900℃IF试验条件下,MCrAlY涂层为韧性金属,涂层中的裂纹是在高温氧化与疲劳机制的交互作用下逐渐萌生的,而试样的失效并不是由涂层的开裂所引起,因此涂层延长合金的疲劳寿命;在IP TMF试验条件下,MCrAlY涂层中没有发现任何裂纹,失效是由于涂层/基体界面的缺陷引起的,涂层延长合金的疲劳寿命;而在OP TMF试验条件下,MCrAlY涂层循环五周内即发生了脆性开裂,裂纹直接贯穿至涂层/基体界面,造成基体中提前萌生疲劳裂纹,因此降低了试样的疲劳寿命。此外,在同等试验条件下HVOF MCrAlY涂层中的裂纹密度较APS MCrAlY涂层小,而且涂层中存在较多未贯穿的短小裂纹,这是由于HVOF MCrAlY涂层具有较低的孔隙率和较大的裂纹扩展阻力的原因。
Nickel base superalloys are widely used for making turbine blades,vanes,and other high-temperature structural components,due to their high yield strength,high creep strength, and good resistance against hot corrosion and oxidation at elevated temperatures.The majority of structural components used in high-temperature applications experience some form of thermomechanical fatigue(TMF) loadings.Some investigations showed that the fatigue life of a real component under thermomechanical fatigue was lower than that under isothermal low-cycle fatigue(IF) at the same maximum temperature and corresponding strain amplitude.Since thermomechanical fatigue test can really simulate the service condition of a high-temperature component in laboratory,it is very important to investigate the damage and failure mechanisms of superalloys working under TMF,which would provide a reliable theoretical basis for design and life prediction of high-temperature structural components.
In this paper,the isothermal low-cycle fatigue behavior of two kinds of cast nickel-based superalloys,i.e.M38 and M963,was investigated at 900℃,and the thermomechanical fatigue behavior and life prediction of M963 in temperature range of 450-900℃were also investigated.Results revealed that both M38 and M963 exhibited a good and stable low-cycle fatigue property.After the comparison of their resistance against oxidation,their strength and ductility at 900℃,it was found that M963 has a similar oxidation resistance,an acceptable ductility,and a much higher high-temperature strength than M38.Therefore,M963 was selected as the material for TMF tests.
Two types of TMF tests were carded out,i.e.in-phase(IP) and out-of-phase(OP). Results revealed that isothermal fatigue exhibited a longer lifetime than both types of TMF at corresponding mechanical strain amplitude in spite of its higher fraction of plastic strain amplitude.This is because the interaction of different deformation mechanisms in high-temperature half cycle and low-temperature half cycle can cause a much severer damage in TMF than in 900℃IF.Moreover,there was a crossover of the IP and OP mechanical strain-life curves.IP fatigue lives were shorter than OP lives at high mechanical strain amplitudes due to creep damage occurred;while IP lives were greater than OP fatigue lives at low mechanical strain amplitudes,which is because the additional damage caused by the tensile mean stress and the oxidation-fatigue interaction in OP.Cracks initiated intergranularly at high mechanical strain amplitude and interdendritically at low mechanical strain amplitude in IP TMF,while totally transgranular cracking occurred in OP TMF.
The Zamrik model and Miller model,which incorporated elastic strain and plastic strain together as damage parameters,can give satisfactory thermomechanical fatigue life prediction by using IF data,while the Ostergren model,which only incorporated plastic strain as TMF damage parameter failed to predict TMF lives.In this paper,a total energy model was proposed to predict TMF lives,result revealed that this model successfully solved the problem that the TMF plastic strain range is so small for high-strength low-ductility superalloys that large errors arise when attempting to either measure it experimentally or predict the TMF life analytically by using the plastic strain range,and a satisfactory prediction result was achieved by using this total energy model.
Since the hot-section components are commonly coated with MCrAlY overlay coatings and thermal barrier coatings consisting of a ceramic topcoat and a MCrAlY bond coat in real applications,it is very important to understand the effect of MCrAlY coatings on fatigue property of components.Therefore,two types of spraying techniques were employed to deposit a MCrAlY overlay coating on superalloy M963,i.e.air plasma spray(APS) and high velocity oxyfuel(HVOF).The cracking mechanisms of MCrAlY coatings and the effect of MCrAIY coatings on failure mechanisms and fatigue life of M963 under 900℃IF and 450-900℃TMF were investigated.Furthermore,comparison of the two types of coating was also made.
Investigations on the effect of MCrAIY coating on failure mechanisms and fatigue lives of M963 under 900℃IF and IP,OP TMF showed that the coating is like a ductile metal in 900℃IF condition,the coating cracks gradually initiated at the surface imperfections by fatigue and oxidation interactions,but the failure of specimen was not caused by coating cracks,therefore the coating had a beneficial effect on fatigue life;In IP TMF condition,the coating also exhibited a beneficial effect on fatigue life,no crack was found in coating after tests,the failure was caused by coating/substrate interface defects;While under OP TMF conditions,brittle cracking of MCrAlY coating occurred in the first five cycles,and then the cracks penetrated to the coating/substrate interface directly.Early cracking of coating under OP TMF conditions accelerated the crack initiation process in superalloy and thus lead to a reduced fatigue life.In addition,it was observed that the crack density in HVOF coating was smaller than that in APS coating,and there existed many small cracks that did not reach the coating/substrate interface in HVOF coating,this is because the HVOF MCrA1Y coating has a lower porosity and a better cracking resistance than the APS one.
本文研究了两种铸造镍基高温合金M38和M963在900℃下的低周疲劳行为,并对M963进行了450-900℃的热机械疲劳行为研究和寿命预测研究。结果表明,M38和M963在900℃下均表现出了良好稳定的低周疲劳性能。将M38与M963在900℃的抗氧化性能、强度和延性加以对比发现,M963具有与M38接近的抗氧化性能,可以接受的延性,以及较为突出的高温强度,适合用来进行条件更为苛刻的热机械疲劳试验。
对M963合金的同相位(IP)和反相位(OP)热机械疲劳研究表明,与同应变速率下的900℃IF相比较,IP和OP TMF总是具有较低的寿命。这是由于热机械疲劳高温半周和低温半周不同形变机制的交互作用导致了热机械疲劳损伤较大的原因。此外,IPTMF和OP TMF的机械应变—疲劳寿命曲线有轻微的交叉现象,当机械应变幅较大时,IP TMF的寿命较低,这是因为在较高的机械应变幅下发生了蠕变损伤;而当机械应变幅较小时,OP TMF的寿命较低,这被认为是OP TMF时的拉伸平均应力以及氧化与疲劳的交互作用发生综合损伤的结果。对断口和剖面分析表明,IP TMF试验条件下,当机械应变幅较大时,疲劳裂纹沿晶萌生,而当机械应变幅较小时,裂纹倾向于在枝晶间萌生;OP TMF试验条件下,所有应变幅时疲劳裂纹都穿晶萌生。
对用等温疲劳数据预测热机械疲劳寿命的研究表明,Zamrik模型和Miller模型能够很好地使用等温疲劳数据预测热机械疲劳寿命,这是因为其损伤参量综合考虑了塑性应变和弹性应变;而只考虑塑性应变的Ostergren模型不能够用等温疲劳数据预测热机械疲劳寿命。本文提出了一种热机械疲劳总能量损伤寿命预测模型,此模型很好地解决了高强度低韧性镍基高温合金热机械疲劳条件下塑性应变幅过低导致无法用其进行寿命预测的问题。
由于实际服役条件下热端部件表面经常涂覆MCrAlY防护涂层和陶瓷热障涂层,因此研究MCrAlY涂层对材料疲劳性能的影响十分重要。本文研究了分别涂覆大气等离子喷涂(APS)和高速氧火焰喷涂(HVOF)MCrAlY涂层的M963合金在900℃等温疲劳及450-900℃热机械疲劳条件下的开裂机制以及涂层对M963合金失效机制和疲劳寿命的影响。
对涂覆MCrAlY涂层的M963合金在900℃IF以及IP和OP TMF试验条件下的失效机制和寿命的研究表明,在900℃IF试验条件下,MCrAlY涂层为韧性金属,涂层中的裂纹是在高温氧化与疲劳机制的交互作用下逐渐萌生的,而试样的失效并不是由涂层的开裂所引起,因此涂层延长合金的疲劳寿命;在IP TMF试验条件下,MCrAlY涂层中没有发现任何裂纹,失效是由于涂层/基体界面的缺陷引起的,涂层延长合金的疲劳寿命;而在OP TMF试验条件下,MCrAlY涂层循环五周内即发生了脆性开裂,裂纹直接贯穿至涂层/基体界面,造成基体中提前萌生疲劳裂纹,因此降低了试样的疲劳寿命。此外,在同等试验条件下HVOF MCrAlY涂层中的裂纹密度较APS MCrAlY涂层小,而且涂层中存在较多未贯穿的短小裂纹,这是由于HVOF MCrAlY涂层具有较低的孔隙率和较大的裂纹扩展阻力的原因。
Nickel base superalloys are widely used for making turbine blades,vanes,and other high-temperature structural components,due to their high yield strength,high creep strength, and good resistance against hot corrosion and oxidation at elevated temperatures.The majority of structural components used in high-temperature applications experience some form of thermomechanical fatigue(TMF) loadings.Some investigations showed that the fatigue life of a real component under thermomechanical fatigue was lower than that under isothermal low-cycle fatigue(IF) at the same maximum temperature and corresponding strain amplitude.Since thermomechanical fatigue test can really simulate the service condition of a high-temperature component in laboratory,it is very important to investigate the damage and failure mechanisms of superalloys working under TMF,which would provide a reliable theoretical basis for design and life prediction of high-temperature structural components.
In this paper,the isothermal low-cycle fatigue behavior of two kinds of cast nickel-based superalloys,i.e.M38 and M963,was investigated at 900℃,and the thermomechanical fatigue behavior and life prediction of M963 in temperature range of 450-900℃were also investigated.Results revealed that both M38 and M963 exhibited a good and stable low-cycle fatigue property.After the comparison of their resistance against oxidation,their strength and ductility at 900℃,it was found that M963 has a similar oxidation resistance,an acceptable ductility,and a much higher high-temperature strength than M38.Therefore,M963 was selected as the material for TMF tests.
Two types of TMF tests were carded out,i.e.in-phase(IP) and out-of-phase(OP). Results revealed that isothermal fatigue exhibited a longer lifetime than both types of TMF at corresponding mechanical strain amplitude in spite of its higher fraction of plastic strain amplitude.This is because the interaction of different deformation mechanisms in high-temperature half cycle and low-temperature half cycle can cause a much severer damage in TMF than in 900℃IF.Moreover,there was a crossover of the IP and OP mechanical strain-life curves.IP fatigue lives were shorter than OP lives at high mechanical strain amplitudes due to creep damage occurred;while IP lives were greater than OP fatigue lives at low mechanical strain amplitudes,which is because the additional damage caused by the tensile mean stress and the oxidation-fatigue interaction in OP.Cracks initiated intergranularly at high mechanical strain amplitude and interdendritically at low mechanical strain amplitude in IP TMF,while totally transgranular cracking occurred in OP TMF.
The Zamrik model and Miller model,which incorporated elastic strain and plastic strain together as damage parameters,can give satisfactory thermomechanical fatigue life prediction by using IF data,while the Ostergren model,which only incorporated plastic strain as TMF damage parameter failed to predict TMF lives.In this paper,a total energy model was proposed to predict TMF lives,result revealed that this model successfully solved the problem that the TMF plastic strain range is so small for high-strength low-ductility superalloys that large errors arise when attempting to either measure it experimentally or predict the TMF life analytically by using the plastic strain range,and a satisfactory prediction result was achieved by using this total energy model.
Since the hot-section components are commonly coated with MCrAlY overlay coatings and thermal barrier coatings consisting of a ceramic topcoat and a MCrAlY bond coat in real applications,it is very important to understand the effect of MCrAlY coatings on fatigue property of components.Therefore,two types of spraying techniques were employed to deposit a MCrAlY overlay coating on superalloy M963,i.e.air plasma spray(APS) and high velocity oxyfuel(HVOF).The cracking mechanisms of MCrAlY coatings and the effect of MCrAIY coatings on failure mechanisms and fatigue life of M963 under 900℃IF and 450-900℃TMF were investigated.Furthermore,comparison of the two types of coating was also made.
Investigations on the effect of MCrAIY coating on failure mechanisms and fatigue lives of M963 under 900℃IF and IP,OP TMF showed that the coating is like a ductile metal in 900℃IF condition,the coating cracks gradually initiated at the surface imperfections by fatigue and oxidation interactions,but the failure of specimen was not caused by coating cracks,therefore the coating had a beneficial effect on fatigue life;In IP TMF condition,the coating also exhibited a beneficial effect on fatigue life,no crack was found in coating after tests,the failure was caused by coating/substrate interface defects;While under OP TMF conditions,brittle cracking of MCrAlY coating occurred in the first five cycles,and then the cracks penetrated to the coating/substrate interface directly.Early cracking of coating under OP TMF conditions accelerated the crack initiation process in superalloy and thus lead to a reduced fatigue life.In addition,it was observed that the crack density in HVOF coating was smaller than that in APS coating,and there existed many small cracks that did not reach the coating/substrate interface in HVOF coating,this is because the HVOF MCrA1Y coating has a lower porosity and a better cracking resistance than the APS one.
引文
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