Analysis of microstructural facet fatigue failure in ultra-fine grained powder metallurgy Ti-6Al-4V produced through hydrogen sintering

Dunstan, Matthew K.; Paramore, James D.; Fang, Z. Zak; Ligda, Jonathan P.; Butler, Brady G.

doi:10.1016/j.ijfatigue.2019.105355

Title: Analysis of microstructural facet fatigue failure in ultra-fine grained powder metallurgy Ti-6Al-4V produced through hydrogen sintering

Abstract

The hydrogen sintering and phase transformation (HSPT) process is a powder metallurgy method that produces Ti-6Al-4V with fatigue properties rivaling wrought processed Ti-6Al-4V. Previous fatigue work on HSPT Ti-6Al-4V has shown failure to be frequently caused by microstructural facets, which were believed to be grain boundary (GB) α phase. This belief conflicts with other reports as fatigue failure typically occurs across α colonies or primary α grains, not GB α. In this work, electron backscattered diffraction is used to identify these facets as GB α. Furthermore, a simple geometric model predicting the effective slip length of GB α is presented.

Authors:

Dunstan, Matthew K. ^[1]; Paramore, James D. ^[1]; Fang, Z. Zak ^[2]; Ligda, Jonathan P. ^[3]; Butler, Brady G. ^[3]

Univ. of Utah, Salt Lake City, UT (United States); United States Army Research Lab., Aberdeen Proving Ground, MD (United States)
Univ. of Utah, Salt Lake City, UT (United States)
United States Army Research Lab., Aberdeen Proving Ground, MD (United States)

Publication Date:: Mon Oct 28 00:00:00 EDT 2019

Research Org.:: Univ. of Utah, Salt Lake City, UT (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

OSTI Identifier:: 1799184

Alternate Identifier(s):: OSTI ID: 1776374

Grant/Contract Number:: EE0005761

Resource Type:: Accepted Manuscript

Journal Name:: International Journal of Fatigue

Additional Journal Information:: Journal Volume: 131; Journal ID: ISSN 0142-1123

Publisher:: Elsevier

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; titanium alloys; fatigue initiation; grain boundary α; electron backscattered diffraction; high cycle fatigue

Citation Formats


                    Dunstan, Matthew K., Paramore, James D., Fang, Z. Zak, Ligda, Jonathan P., and Butler, Brady G. Analysis of microstructural facet fatigue failure in ultra-fine grained powder metallurgy Ti-6Al-4V produced through hydrogen sintering.  United States: N. p., 2019. 
Web.  doi:10.1016/j.ijfatigue.2019.105355.

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                    Dunstan, Matthew K., Paramore, James D., Fang, Z. Zak, Ligda, Jonathan P., & Butler, Brady G. Analysis of microstructural facet fatigue failure in ultra-fine grained powder metallurgy Ti-6Al-4V produced through hydrogen sintering.  United States.  https://doi.org/10.1016/j.ijfatigue.2019.105355

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                    Dunstan, Matthew K., Paramore, James D., Fang, Z. Zak, Ligda, Jonathan P., and Butler, Brady G. Mon .  
"Analysis of microstructural facet fatigue failure in ultra-fine grained powder metallurgy Ti-6Al-4V produced through hydrogen sintering".  United States.  https://doi.org/10.1016/j.ijfatigue.2019.105355.  https://www.osti.gov/servlets/purl/1799184.

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@article{osti_1799184,

  title        = {Analysis of microstructural facet fatigue failure in ultra-fine grained powder metallurgy Ti-6Al-4V produced through hydrogen sintering},

  author       = {Dunstan, Matthew K. and Paramore, James D. and Fang, Z. Zak and Ligda, Jonathan P. and Butler, Brady G.},

  abstractNote = {The hydrogen sintering and phase transformation (HSPT) process is a powder metallurgy method that produces Ti-6Al-4V with fatigue properties rivaling wrought processed Ti-6Al-4V. Previous fatigue work on HSPT Ti-6Al-4V has shown failure to be frequently caused by microstructural facets, which were believed to be grain boundary (GB) α phase. This belief conflicts with other reports as fatigue failure typically occurs across α colonies or primary α grains, not GB α. In this work, electron backscattered diffraction is used to identify these facets as GB α. Furthermore, a simple geometric model predicting the effective slip length of GB α is presented.},

  doi          = {10.1016/j.ijfatigue.2019.105355},

  journal      = {International Journal of Fatigue},

  number       = ,

  volume       = 131,

  place        = {United States},

  year         = {Mon Oct 28 00:00:00 EDT 2019},

  month        = {Mon Oct 28 00:00:00 EDT 2019}

}

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Title: Analysis of microstructural facet fatigue failure in ultra-fine grained powder metallurgy Ti-6Al-4V produced through hydrogen sintering

Abstract

Citation Formats

Spark plasma sintering of commercial and development titanium alloy powders journal, April 2015

Fatigue behavior of beta processed titanium alloy IMI 685 journal, June 1977

Investigation of Fatigue Crack Initiation in Ti-6Al-4V During Tensile-Tensile Fatigue journal, April 2002

Local texture and fatigue crack initiation in a Ti-6Al-4V titanium alloy: FATIGUE CRACK INITIATION IN Ti-6Al-4V TITANIUM ALLOY journal, May 2002

Slip and fatigue crack formation processes in an α/β titanium alloy in relation to crystallographic texture on different scales journal, September 2008

Gaseous isostatic forging: Design and application to powder metallurgy Ti-6Al-4V journal, September 2018

Determination of crystallographic orientation of dwell-fatigue fracture facets in Ti-6242 alloy journal, October 2007

An experimental study of the (Ti–6Al–4V)–xH phase diagram using in situ synchrotron XRD and TGA/DSC techniques journal, February 2015

Improvements in the fatigue strength of Ti-6Al-4V through microstructure control journal, June 1974

Electron Backscattering Pattern Identification of Surface Morphology of Fatigue Cracks in ta6v journal, December 1994

Powder metallurgy of titanium – past, present, and future journal, August 2017

The effect of the alpha-phase volume fraction and stress ratio on the fatigue crack growth characteristics of the near-alpha IMI 834 Ti alloy journal, July 1992

Phase Transformations and Formation of Ultra-Fine Microstructure During Hydrogen Sintering and Phase Transformation (HSPT) Processing of Ti-6Al-4V journal, September 2015

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LXIII. On the division of space with minimum partitional area journal, December 1887

Sintering behavior and microstructure evolution in cp-titanium processed by spark plasma sintering journal, January 2018

Effect of microstructure on notch fatigue properties of Ti-6Al-4V journal, December 1976

A powder metallurgy method for manufacturing Ti-6Al-4V with wrought-like microstructures and mechanical properties via hydrogen sintering and phase transformation (HSPT) journal, October 2015

Dwell-sensitive fatigue under biaxial loads in the near-alpha titanium alloy IMI685 journal, January 1994

Crystallography of fracture facets in a near-alpha titanium alloy journal, June 2006

Fatigue crack propagation in titanium alloys with lamellar and bi-lamellar microstructures journal, December 2001

The mechanism of void formation, void growth, and tensile fracture in an alloy consisting of two ductile phases journal, October 1972

Understanding competing fatigue mechanisms in powder metallurgy Ti–6Al–4V alloy: Role of crack initiation and duality of fatigue response journal, April 2015

The effects of microstructure and porosity on the competing fatigue failure mechanisms in powder metallurgy Ti-6Al-4V journal, November 2018

Titanium Powder Metallurgy for Automotive Components journal, January 2002

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A novel chemical pathway for energy efficient production of Ti metal from upgraded titanium slag journal, February 2016

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The interrelationship of fracture toughness and microstructure in a Ti-5.25Al-5.5V-0.9Fe-0.5Cu alloy journal, March 1971

Microstructure and the development of fatigue cracks at notches journal, May 1999

Microstructural Influences on Very-High-Cycle Fatigue-Crack Initiation in Ti-6246 journal, August 2008

MICROSTRUCTURAL EFFECTS ON SMALL FATIGUE CRACK INITIATION AND GROWTH IN Ti6A14V ALLOYS journal, December 1995

Producing lower-cost titanium for automotive applications journal, September 1998

Crystallography of Fatigue Crack Initiation and Growth in Fully Lamellar Ti-6Al-4V journal, November 2009

Direct electrochemical reduction of titanium dioxide to titanium in molten calcium chloride journal, September 2000

Titanium Metal Injection Molding - A Commercial Overview journal, August 2016

Hydrogen-enabled microstructure and fatigue strength engineering of titanium alloys journal, February 2017

Stage I fatigue crack propagation in a titanium alloy journal, May 1988

Spark plasma sintering of commercial and development titanium alloy powders
journal, April 2015

Fatigue behavior of beta processed titanium alloy IMI 685
journal, June 1977

Investigation of Fatigue Crack Initiation in Ti-6Al-4V During Tensile-Tensile Fatigue
journal, April 2002

Local texture and fatigue crack initiation in a Ti-6Al-4V titanium alloy: FATIGUE CRACK INITIATION IN Ti-6Al-4V TITANIUM ALLOY
journal, May 2002

Slip and fatigue crack formation processes in an α/β titanium alloy in relation to crystallographic texture on different scales
journal, September 2008

Gaseous isostatic forging: Design and application to powder metallurgy Ti-6Al-4V
journal, September 2018

Determination of crystallographic orientation of dwell-fatigue fracture facets in Ti-6242 alloy
journal, October 2007

An experimental study of the (Ti–6Al–4V)–xH phase diagram using in situ synchrotron XRD and TGA/DSC techniques
journal, February 2015

Improvements in the fatigue strength of Ti-6Al-4V through microstructure control
journal, June 1974

Electron Backscattering Pattern Identification of Surface Morphology of Fatigue Cracks in ta6v
journal, December 1994

Powder metallurgy of titanium – past, present, and future
journal, August 2017

The effect of the alpha-phase volume fraction and stress ratio on the fatigue crack growth characteristics of the near-alpha IMI 834 Ti alloy
journal, July 1992

Phase Transformations and Formation of Ultra-Fine Microstructure During Hydrogen Sintering and Phase Transformation (HSPT) Processing of Ti-6Al-4V
journal, September 2015

FAST-forge − A new cost-effective hybrid processing route for consolidating titanium powder into near net shape forged components
journal, May 2017

LXIII. On the division of space with minimum partitional area
journal, December 1887

Sintering behavior and microstructure evolution in cp-titanium processed by spark plasma sintering
journal, January 2018

Effect of microstructure on notch fatigue properties of Ti-6Al-4V
journal, December 1976

A powder metallurgy method for manufacturing Ti-6Al-4V with wrought-like microstructures and mechanical properties via hydrogen sintering and phase transformation (HSPT)
journal, October 2015

Dwell-sensitive fatigue under biaxial loads in the near-alpha titanium alloy IMI685
journal, January 1994

Crystallography of fracture facets in a near-alpha titanium alloy
journal, June 2006

Fatigue crack propagation in titanium alloys with lamellar and bi-lamellar microstructures
journal, December 2001

The mechanism of void formation, void growth, and tensile fracture in an alloy consisting of two ductile phases
journal, October 1972

Understanding competing fatigue mechanisms in powder metallurgy Ti–6Al–4V alloy: Role of crack initiation and duality of fatigue response
journal, April 2015

The effects of microstructure and porosity on the competing fatigue failure mechanisms in powder metallurgy Ti-6Al-4V
journal, November 2018

Titanium Powder Metallurgy for Automotive Components
journal, January 2002

New Powder Metallurgical Approach to Achieve High Fatigue Strength in Ti-6Al-4V Alloy
journal, February 2016

A novel chemical pathway for energy efficient production of Ti metal from upgraded titanium slag
journal, February 2016

Fatigue Performance of Powder Metallurgy (PM) Ti-6Al-4V Alloy: A Critical Analysis of Current Fatigue Data and Metallurgical Approaches for Improving Fatigue Strength
journal, January 2016

The interrelationship of fracture toughness and microstructure in a Ti-5.25Al-5.5V-0.9Fe-0.5Cu alloy
journal, March 1971

Microstructure and the development of fatigue cracks at notches
journal, May 1999

Microstructural Influences on Very-High-Cycle Fatigue-Crack Initiation in Ti-6246
journal, August 2008

MICROSTRUCTURAL EFFECTS ON SMALL FATIGUE CRACK INITIATION AND GROWTH IN Ti6A14V ALLOYS
journal, December 1995

Producing lower-cost titanium for automotive applications
journal, September 1998

Crystallography of Fatigue Crack Initiation and Growth in Fully Lamellar Ti-6Al-4V
journal, November 2009

Direct electrochemical reduction of titanium dioxide to titanium in molten calcium chloride
journal, September 2000

Titanium Metal Injection Molding - A Commercial Overview
journal, August 2016

Hydrogen-enabled microstructure and fatigue strength engineering of titanium alloys
journal, February 2017

Stage I fatigue crack propagation in a titanium alloy
journal, May 1988