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Prediction of Creep Behavior of Ni-Base Superalloy based on Continuum Damage Mechanics Approach

Prediction of Creep Behavior of Ni-Base Superalloy based on Continuum Damage Mechanics Approach

Date4th Mar 2024

Time03:00 PM

Venue Online

PAST EVENT

Details

A study was conducted to investigate creep damage mechanisms and predict the creep behavior of a directionally solidified nickel-based superalloy (DSCM247) at three different temperatures: 850°C, 950°C, and 1050°C, while subjecting the material to a stress range spanning from 150MPa to 500MPa using the concepts of -Projection technique and continuum damage mechanics (CDM) approach. The alternating current potential drop (ACPD) technique has been employed for damage measurement during creep. Detailed microstructure and damage evolution during creep of specimens with and without notch were characterized using ACPD, scanning electron microscopy (SEM), electron back scattered diffraction (EBSD) techniques. Creep tests were conducted on DSCM247, a nickel-base superalloy, using specimens at three distinct temperatures: 850°C, 950°C, and 1050°C. Creep curve predictions were carried out using a methodology based on -Projection technique and a computer code based on MATLAB. The predicted creep data was validated with the experimental creep data at the three temperatures. By expanding the 'in-house developed strategy' of predicting the creep curves based on -Projection methodology, three-dimensional (3D) maps representing creep curves (illustrating the link between creep strain, time, and stress) were constructed. The resulting 3D maps with experimental creep curves overlay demonstrate excellent agreement between the two. A comparison of the stress rupture time data predicted by both the Larson-Miller parameter (LMP) approach and the -Projection method with the experimental data has revealed that a clear deviation of time to rupture values predicted by the LMP method from the experimental values at lower stresses. However, an excellent agreement of the time to rupture values predicted by the -based approach, with experimental data at lower stresses, has been observed thereby demonstrates the superior ability of the -Projection method for accurate prediction of long-term stress rupture data. In this current investigation, an effort has been undertaken to fully uncover the capabilities of the ACPD technique for assessing creep strain. The creep strains determined from the potential drop data acquired through the utilization of the ACPD technique exhibited a satisfactory level of concurrence with the creep strains that were monitored using LVDT measurements in the course of conducting creep tests on a DSCM247 alloy across various testing parameters. While the creep data obtained by both LVDT and ACPD techniques match quite well in case of smooth (notch-free) specimens, the creep data obtained by both these techniques do not match in case of notched specimens. This behavior arises because the LVDT technique measures the average strain across the gauge length, whereas strain accumulation is more concentrated in the notched region of the specimens. Consequently, the ACPD technique captures the creep strain that is specifically localized within the notch area. This aspect has been verified by measuring the local strain in the notch using a non-contacting laser gaging technique. The work therefore proves the ACPD technique's capability to quantify local creep strain in the notch location without the necessity of the specialized instruments like laser gaging system. Additionally, in the context of CDM, an effort has been made to combine the damage evolution observed during creep utilizing the ACPD technique with the creep constitutive equation (power-law) to forecast the alloys creep properties. The overall deformation and damage accumulation during creep of DSCM247 alloy at 850°C/500 MPa, 950°C/250MPa & 1050°C/125MPa by interrupting creep tests at different strain levels are captured using ACPD. The data depicting the evolution of damage acquired from creep tests performed under identical stress and temperature conditions, utilizing the ACPD technique for both smooth and notched specimens were coupled with creep constitution equation to generate/predict creep curves following the concepts of strain equivalence hypothesis of CDM and validated with experimental creep curves. Also, a methodology based on CDM concept has been developed to predict important creep parameters such as threshold creep strain (th), critical creep strain (cr) and time to rupture (tr) and validated with experimental values. Further, the CDM predicted th, cr and tr values as well as the values derived from the creep curved predicted by Projection technique were successfully validated with the experimental values. The studies utilizing the ACPD technique illustrate its capacity to serve as a valuable non-destructive approach for real-time assessment of creep strain and damage within components. Microstructural/damage evolution with creep strain has been characterized using SEM and EBSD on the creep specimens tested till rupture, as well as the specimens interrupted at different strain levels at 850°C (500MPa), 950°C (250MPa) and 1050°C (125MPa) for both smooth and notched specimens. Detailed microstructural studies on specimens interrupted at different creep strain levels revealed that microstructural change in terms of directional coarsening of ' precipitates i.e., rafting perpendicular to the creep stress axis, widening of  matrix channel was observed in DSCM247 alloy. However, rafting was not observed in creep specimens tested at 850°C due to lower diffusion rates. Dynamic recrystallization, creep-induced cavitation, and surface cracking have been noted in specimens with both smooth and notched configurations subjected to testing at elevated temperatures of 950°C and 1050°C, especially under higher levels of creep strain. However, dynamic recrystallization has not been observed in creep specimens tested at 850°C due to lower diffusion rates. Finally, an investigation was conducted to understand the mechanisms accountable for the sustained acceleration of the creep rate, resulting in the prolonged occurrence of tertiary creep behavior in the DSCM247 alloy, in the context of nickel-based superalloys, investigating the mechanisms attributed to the identification of factors accountable for the premature initiation and prolonged occurrence of tertiary creep, which is notable in these alloys. In all the cases, shape of the creep curves of the superalloy DSCM247 alloy is marked by a prevailing stage of significant and continuous tertiary creep regime with limited extent of the primary and secondary stages of creep behavior. The acceleration in creep rate due to the accumulation of creep strain during the tertiary creep regime of the DSCM247 alloy signifies that the initiation of tertiary creep in this alloy originates from strain softening. Initially, a clear correlation between creep rate and the buildup of creep strain was observed at lower strain levels across all experimental conditions. Nevertheless, once a specific strain threshold was surpassed (ranging from 5% to 13% depending on the applied stress), the creep rate exhibited a more pronounced escalation, departing from the previous linear trend. This abrupt elevation in creep rate beyond the established threshold can be attributed to the continuous amplification of stress on specimens subjected to consistent load conditions. Initially, the linear softening linked to the rise in mobile dislocation density during the initiation of the tertiary creep phase is eventually supplanted by exponential softening (manifested as an external loss of material) as the deformation progresses further, persisting for extended durations. Dynamic recrystallization and cavitational damage followed by oxidation induced surface cracking are the mechanisms responsible for the acceleration in creep rate late in the tertiary stage.

Speakers

Mr. Chiptalluri M Omprakash, (MM12D016)

Department of Metallurgical and Materials Engineering