Fatigue resistance of the grain size transition zone in a dual microstructure superalloy disk

Mechanical property requirements vary with location in nickel-based superalloy disks In order to maximize the associated mechanical properties heat treatment methods have been developed for producing tailored microstructures In this study a specialized heat treatment method was applied to produce varying grain microstructures from the bore to the rim portions of a powder metallurgy processed nickel-based superalloy disk The bore of the contoured disk consisted of fine grains to maximize strength and fatigue resistance at lower temperatures The nm microstructure of the disk consisted of coarse grains for maximum resistance to creep and dwell crack growth at high temperatures up to 704 degrees C However the fatigue resistance of the grain size transition zone was unclear and needed to be evaluated This zone was located as a band in the disk web between the bore and rim Specimens were extracted parallel and transverse to the transition zone and multiple fatigue tests were performed at 427 degrees C and 704 degrees C Mean fatigue lives were lower at 427 degrees C than 704 degrees C Specimen failures often initiated at relatively large grains which failed on crystallographic facets Grain size distributions were characterized in the specimens and related to the grains initiating failures as well as location within the transition zone Fatigue life decreased with increasing maximum grain size Correspondingly mean fatigue resistance of the transition zone was slightly higher than that of the rim but lower than that of the bore The scatter in limited tests of replicates was comparable for all transition zone locations examined Published by Elsevier Ltd