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Title: The onset and evolution of fatigue-induced abnormal grain growth in nanocrystalline Ni–Fe

Conventional structural metals suffer from fatigue-crack initiation through dislocation activity which forms persistent slip bands leading to notch-like extrusions and intrusions. Ultrafine-grained and nanocrystalline metals can potentially exhibit superior fatigue-crack initiation resistance by suppressing these cumulative dislocation activities. Prior studies on these metals have confirmed improved high-cycle fatigue performance. In the case of nano-grained metals, analyses of subsurface crack initiation sites have indicated that the crack nucleation is associated with abnormally large grains. But, these post-mortem analyses have led to only speculation about when abnormal grain growth occurs (e.g., during fatigue, after crack initiation, or during crack growth). In this study, a recently developed synchrotron X-ray diffraction technique was used to detect the onset and progression of abnormal grain growth during stress-controlled fatigue loading. Our study provides the first direct evidence that the grain coarsening is cyclically induced and occurs well before final fatigue failure—our results indicate that the first half of the fatigue life was spent prior to the detectable onset of abnormal grain growth, while the second half was spent coarsening the nanocrystalline structure and cyclically deforming the abnormally large grains until crack initiation. Post-mortem fractography, coupled with cycle-dependent diffraction data, provides the first details regarding the kineticsmore » of this abnormal grain growth process during high-cycle fatigue testing. Finally, precession electron diffraction images collected in a transmission electron microscope after the in situ fatigue experiment also confirm the X-ray evidence that the abnormally large grains contain substantial misorientation gradients and sub-grain boundaries.« less
Authors:
 [1] ;  [2] ;  [2] ;  [3] ;  [3] ;  [1]
  1. Sandia National Lab. (SNL-NM), Albuquerque, NM (United States). Materials Science and Engineering Center
  2. SLAC National Accelerator Lab., Menlo Park, CA (United States). Stanford Synchrotron Radiation Lightsource (SSRL)
  3. Sandia National Lab. (SNL-NM), Albuquerque, NM (United States). Physical, Chemical, and Nano Sciences Center
Publication Date:
Report Number(s):
SAND2016-9571J
Journal ID: ISSN 0022-2461; PII: 437
Grant/Contract Number:
AC04-94AL85000
Type:
Accepted Manuscript
Journal Name:
Journal of Materials Science
Additional Journal Information:
Journal Volume: 52; Journal Issue: 1; Journal ID: ISSN 0022-2461
Publisher:
Springer
Research Org:
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Sponsoring Org:
USDOE Office of Science (SC), Basic Energy Sciences (BES) (SC-22); USDOE National Nuclear Security Administration (NNSA)
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; nanocrystalline; fatigue; fracture; crack initiation; grain coarsening; abnormal grain growth
OSTI Identifier:
1338674

Furnish, T. A., Mehta, A., Van Campen, D., Bufford, D. C., Hattar, K., and Boyce, B. L.. The onset and evolution of fatigue-induced abnormal grain growth in nanocrystalline Ni–Fe. United States: N. p., Web. doi:10.1007/s10853-016-0437-z.
Furnish, T. A., Mehta, A., Van Campen, D., Bufford, D. C., Hattar, K., & Boyce, B. L.. The onset and evolution of fatigue-induced abnormal grain growth in nanocrystalline Ni–Fe. United States. doi:10.1007/s10853-016-0437-z.
Furnish, T. A., Mehta, A., Van Campen, D., Bufford, D. C., Hattar, K., and Boyce, B. L.. 2016. "The onset and evolution of fatigue-induced abnormal grain growth in nanocrystalline Ni–Fe". United States. doi:10.1007/s10853-016-0437-z. https://www.osti.gov/servlets/purl/1338674.
@article{osti_1338674,
title = {The onset and evolution of fatigue-induced abnormal grain growth in nanocrystalline Ni–Fe},
author = {Furnish, T. A. and Mehta, A. and Van Campen, D. and Bufford, D. C. and Hattar, K. and Boyce, B. L.},
abstractNote = {Conventional structural metals suffer from fatigue-crack initiation through dislocation activity which forms persistent slip bands leading to notch-like extrusions and intrusions. Ultrafine-grained and nanocrystalline metals can potentially exhibit superior fatigue-crack initiation resistance by suppressing these cumulative dislocation activities. Prior studies on these metals have confirmed improved high-cycle fatigue performance. In the case of nano-grained metals, analyses of subsurface crack initiation sites have indicated that the crack nucleation is associated with abnormally large grains. But, these post-mortem analyses have led to only speculation about when abnormal grain growth occurs (e.g., during fatigue, after crack initiation, or during crack growth). In this study, a recently developed synchrotron X-ray diffraction technique was used to detect the onset and progression of abnormal grain growth during stress-controlled fatigue loading. Our study provides the first direct evidence that the grain coarsening is cyclically induced and occurs well before final fatigue failure—our results indicate that the first half of the fatigue life was spent prior to the detectable onset of abnormal grain growth, while the second half was spent coarsening the nanocrystalline structure and cyclically deforming the abnormally large grains until crack initiation. Post-mortem fractography, coupled with cycle-dependent diffraction data, provides the first details regarding the kinetics of this abnormal grain growth process during high-cycle fatigue testing. Finally, precession electron diffraction images collected in a transmission electron microscope after the in situ fatigue experiment also confirm the X-ray evidence that the abnormally large grains contain substantial misorientation gradients and sub-grain boundaries.},
doi = {10.1007/s10853-016-0437-z},
journal = {Journal of Materials Science},
number = 1,
volume = 52,
place = {United States},
year = {2016},
month = {10}
}