Effect of Residual Stress Induced by Different Cooling Methods in Heat Treatment on the Fatigue Crack Propagation Behaviour of GH4169 Disc
Abstract
:1. Introduction
2. Disc Design and Residual Stress Introduction
2.1. Material Properties and Disc Design
2.2. Formation of Residual Stress by AJC
2.3. Residual Stress Analysis of Different Cooling Ways in Heat Treatment
3. Crack Propagation Test
3.1. Prefabrication of Initial Cracks
3.2. Fatigue Test Plan
3.3. Test Results
3.3.1. Disc Life Statistics and Failure Modes
3.3.2. External Surface Morphology Detection of Crack
3.3.3. Fracture Morphology of the Inner Surface of the Crack
4. Analysis and Discussion
5. Conclusions
- (1)
- Different cooling methods in solid solution were adopted to determine the residual stress distribution near the central hole of the discs. Amongst the methods mentioned above, the AJC method could induce about 259 MPa residual compression stress within the range of 6 mm from the surface of the central hole. WQ method results in a smaller range and value of residual compressive stress. In the area 3 mm outside the central hole surface, the residual stress mainly exists in the form of tensile stress. Almost no residual stress occurred near the central hole of the disc after AC because of its low cooling rate. The comparison showed that the AJC method effectively induces appropriate residual compressive stress.
- (2)
- The LCF crack propagation test of five prefabricated discs with initial cracks was carried out on the HR6DI rotor high-speed rotating tester. The crack growth life of D01 (AJC at 47,500 rpm), D02 (AC at 47,500 rpm), D03 (WQ at 47,500 rpm), D04 (AJC at 45,000 rpm) and D05 (WQ at 47,500 rpm) was 3497, 3160, 2827, 3888 and 2860, respectively. When the maximum speed of the test was 47,500 rpm, the crack propagation life of the disc cooled by air jetting was 10.7% higher than that of the disc cooled naturally in the air. The crack propagation life of the disc cooled by air jetting was 23.7% higher than that of the water-cooled disc. When the maximum speed of the test dropped to 45,000 rpm, the crack propagation life of the disc cooled by air jetting was 35.9% higher than that of the water-cooled disc. The import of residual compressive stress field near the central hole by AJC effectively inhibited crack propagation. When the fatigue load was low, this inhibition effect was more significant.
- (3)
- By taking the linear superposition of residual stress and centrifugal force as the driving force of crack propagation, the crack propagation life of different wheel discs was analysed and calculated using FRANC3D. The results agreed with the results of surface replica and fractured back extrapolation, which proved the feasibility and accuracy of this method. Comparison of the surface replica and fracture back extrapolation results of different heat treatment discs at 47,500 and 45,000 rpm showed that the mechanism of residual stress affecting crack propagation was that compressive stress would inhibit the opening of the crack surface during crack propagation to prevent the initiation and propagation of the crack, whereas residual tensile stress would make the opening of the crack surface easier to have the opposite effect. Therefore, the influence of residual tensile stress should be avoided in material processing.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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GH4169 (500 °C) | |
---|---|
Yield stress σ0.2 (MPa) | 1050 |
Ultimate tensile strength σb (MPa) | 1260 |
Poisson’s ratio ν | 0.33 |
Young’s modulus E (GPa) | 175 |
) | 18 |
) | 101.3 |
Temperature °C | Thermal Conductivity | Density | Specific Heat Capacity | Coefficient of Thermal Expansion 10−6 | Thermal Convective Coefficient | Young’s Modulus GPa |
---|---|---|---|---|---|---|
0 | 11.02 | 8226 | 424 | 12.8 | 4000 | 197 |
100 | 12.75 | 8190 | 434 | 13.1 | 4500 | 197 |
200 | 14.36 | 8160 | 448 | 13.4 | 4400 | 197 |
300 | 15.96 | 8130 | 463 | 13.8 | 4050 | 197 |
400 | 17.60 | 8090 | 480 | 14.2 | 3660 | 197 |
500 | 19.18 | 8050 | 500 | 14.0 | 3330 | 196 |
600 | 20.77 | 8010 | 525 | 15.1 | 2880 | 194 |
700 | 22.36 | 7960 | 560 | 15.7 | 2700 | 187 |
800 | 23.95 | 7910 | 605 | 16.4 | 2520 | 165 |
850 | 24.53 | 7890 | 625 | 16.8 | - | 145 |
900 | 25.10 | 7860 | 636 | 17.1 | 1800 | 130 |
1000 | 26.83 | 7810 | 645 | 17.5 | 1000 | 105 |
Cooling Method | AJC | AC | WQ | |
---|---|---|---|---|
Max Speed | ||||
47,500 rpm | D01 | D02 | D03 | |
45,000 rpm | D04 | - | D05 |
Test Parameter | Value |
---|---|
Disk temperature | 500 ± 5 °C |
Chamber vacuum degree | <100 Pa |
Maximum rotation speed | 47,500/45,000 rpm |
Minimum rotation speed | 3150 rpm |
Disk acceleration | 400 r/(min·s) |
Disk Num. | Crack Growth Life | Max Rotation Speed | Cooling Method |
---|---|---|---|
D01 | 3497 | 47,500 | AJC |
D02 | 3160 | 47,500 | AC |
D03 | 2827 | 47,500 | WQ |
D04 | 3888 | 45,000 | AJC |
D05 | 2860 | 45,000 | WQ |
Test Life | Predicted Life | Error Percentage | |
---|---|---|---|
D01-AJC method (maximum speed is 47,500 rpm) | 3497 | 3421 | −2.17% |
D02-AC method (maximum speed is 47,500 rpm) | 3160 | 3012 | −4.68% |
D03-WQ method (maximum speed is 47,500 rpm) | 2827 | 2823 | −0.14% |
D04-AJC method (maximum speed is 45,000 rpm) | 3888 | 4506 | 15.9% |
D05-WQ method (maximum speed is 45,000 rpm) | 2860 | 3674 | 28.5% |
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Fan, M.; Chen, C.; Xuan, H.; Qin, H.; Qu, M.; Shi, S.; Bi, Z.; Hong, W. Effect of Residual Stress Induced by Different Cooling Methods in Heat Treatment on the Fatigue Crack Propagation Behaviour of GH4169 Disc. Materials 2022, 15, 5228. https://0-doi-org.brum.beds.ac.uk/10.3390/ma15155228
Fan M, Chen C, Xuan H, Qin H, Qu M, Shi S, Bi Z, Hong W. Effect of Residual Stress Induced by Different Cooling Methods in Heat Treatment on the Fatigue Crack Propagation Behaviour of GH4169 Disc. Materials. 2022; 15(15):5228. https://0-doi-org.brum.beds.ac.uk/10.3390/ma15155228
Chicago/Turabian StyleFan, Menglong, Chuanyong Chen, Haijun Xuan, Hailong Qin, Mingmin Qu, Songyi Shi, Zhongnan Bi, and Weirong Hong. 2022. "Effect of Residual Stress Induced by Different Cooling Methods in Heat Treatment on the Fatigue Crack Propagation Behaviour of GH4169 Disc" Materials 15, no. 15: 5228. https://0-doi-org.brum.beds.ac.uk/10.3390/ma15155228