Study on low-cycle fatigue life of nickel-based superalloy GH4586 at various temperatures
-
Yixin Ma
,
Bingyang Liu
Abstract
The nickel-based superalloy GH4586 has been more widely used as the main material for the preparation of aerospace turbine components. However, with the development of reusable rocket engine technology, a more profound understanding of the low-cycle fatigue performance of the material under cyclic loading is required. In this study, the same specification of GH4586 used in the turbine disk of an engine is used to prepare test specimens, the fatigue performance at different strain levels of 0.5, 0.7, 0.9 and 1% is investigated, and fatigue tests are carried out at six temperatures from room temperature to 1,173 K. The fatigue σ–N curves of the material are obtained. In this study, the cyclic hardening/softening transformation mechanism of GH4586 alloy and its influence on the life of turbine components are systematically revealed through low-cycle fatigue tests with multiple temperature points (room temperature to 1,173 K) and multiple strain amplitudes (0.5–1%). The study shows that optimizing the strain amplitude below 900 K can improve the component life by more than 20%, which provides a quantitative basis for the strain–temperature coupling design of reusable rocket engine turbine.
1 Introduction
Reducing the cost of space activities has become an important goal and direction of space development [1]. Reuse is one of the most important ways to reduce the cost of space launches, and reusable launch vehicles, which can achieve reuse and significantly reduce the cost of launching a unit payload, have become an important development direction for the current space transport systems [2].
Reusable rockets not only have much lower launch costs than traditional rockets but also have the advantages of low technical difficulty and early operational readiness compared to space vehicles, making them the preferred option for reusable vehicles; there are already some successful cases of reusable rocket development abroad [3,4]. Compared to traditional expendable rockets, which are designed for performance and reliability for a single mission, reusable rockets have higher requirements for engine performance and cyclic life [5].
Turbine is one of the most complex components in a rocket engine and the most critical component limiting the life of the engine [6,7]. As a key component affecting the performance and cyclic life of the engine, the turbine blade produces a large plastic strain under cyclic thermal, centrifugal, and aerodynamic loads resulting in crack initiation up to fracture [8,9]. Erickson et al. [10] investigated the tensile and fatigue data of superalloy at 400°C and proposed a correction to the damage parameters, which are suitable for elasticity-dominated fatigue life prediction but are not applicable to the low-cycle fatigue condition. Gulczyński et al. [11] evaluated low-cycle fatigue of the turbine blade of a reusable rocket engine based on the nickel-based superalloys at 500 K Coffin–Manson formula for life prediction. All of these studies only carried out low-cycle fatigue analyses at a certain temperature.
The study of the low-cycle fatigue behavior of nickel-based superalloys can be traced back to the systematic exploration of aero-engine materials in the 1970s [12]. Early studies focused on the cyclic response mechanism of single-crystal alloys (e.g., CMSX-4) [13], while in recent years, much attention has been paid to the relationship between strain localization and crack initiation in polycrystalline alloys (e.g., Inconel 718) [14]. However, there is still a gap in the study of the multi-temperature fatigue properties of GH4586, a high γ′-phase volume fraction (>50%) alloy [15], especially its dynamic strain aging effect at high temperatures has not been clarified.
In the process of thermal load cycling, the temperature range is generally large, but few studies have been carried out to investigate the low-cycle fatigue performance of turbine materials at multiple temperature points, which can cause inaccuracies in the process of estimating the low-cycle life of turbines. GH4586, a nickel-based superalloy, plays a vital role in the aerospace industry. Especially in rocket engines, the use of GH4586 is crucial to improve the performance and reliability of the engines. By investigating the low-cycle fatigue of GH4586 alloy at different temperatures, this study aims to provide a scientific basis for the design and material selection of reusable rocket engines.
2 Experimental setup
2.1 Experiment method
The test equipment for cyclic loading material tests is a hydraulic servo fatigue tester, as shown in Table 1 and Figure 1 (left). The temperature control system GW900 is heated by a high-temperature electric heating alloy wire with a temperature fluctuation of less than ±2°C. The system includes a temperature sensor and a feedback regulator to ensure temperature stability and consistency throughout the experiment. In order to eliminate variables other than the preset ones, all specimens for this test are prepared from the same batch of bars with the dimensions shown in Figure 1 (lower right). Specimens were 106 mm in total length, with a test section length of 46 mm, and a minimum diameter of 5 mm according to GB/T 15248-2008 [16].
MTS hydraulic servo fatigue testing machine parameters
| Instrument types | 370.10 |
| Load | Maximum static load: ±50, ±100 kN, maximum dynamic load: ±50 kN |
| Load accuracy | Static force: ±0.5%, dynamic force: ±1% |
| Concentricity | ±5% |
| Testing temperature | Room temperature: ∼900°C |
| Temperature error | ≤±2°C |
| Testing frequency | 0–50 Hz |
| Type of load | Axial force tension-compression testing |
Test setup and loading conditions.
The loading conditions during the test are all chosen to be sinusoidal, with a constant single cycle length, varying only the strain amplitude. Based on the above test setup, the subsequent test arrangement can be obtained. Given the application of GH4586 at elevated temperatures, oxidation and corrosion are two critical environmental factors that can significantly affect material performance. In order to control these factors, our experiments were conducted in a controlled protective atmosphere to minimize the effects of oxidation and corrosion on the fatigue test results.
2.2 Experimental arrangements
The test is conducted at six temperature points: room temperature (RT), 600, 700, 900, 1,100, and 1,173 K. Strain levels of 0.5, 0.7, 0.9, and 1% have been chosen because these values cover the range of strains likely to be encountered by the GH4586 during operation of rocket motor turbine. These strain levels reflect the stress state of the material under actual service conditions, including cyclic loading during start-up, operation, and shutdown. Each temperature point is tested for low-cycle fatigue life at four strain amplitudes, and is repeated three times at a strain amplitude of 0.9% in the steady-state section of the turbine in order to eliminate the randomness in the data. The final test configuration is shown in Table 2.
Working condition list
| T(K) | Variable | Amplitude | Average | Strain ratio | Strain rate | Cycle number | Specimen |
|---|---|---|---|---|---|---|---|
| RT, 600, 700, 900, 1,100, 1,173 | Strain | 0.005 | 0 | −1 | 0.002 | 1,000 | 1 |
| Strain | 0.007 | 0 | −1 | 0.002 | 800 | 1 | |
| Strain | 0.009 | 0 | −1 | 0.002 | 600 | 3 | |
| Strain | 0.01 | 0 | −1 | 0.002 | 500 | 1 |
3 Results and discussion
Due to the large number of tests involved in this study, the results of the multi-cycle stress amplitude at different temperatures and strain amplitudes will be compared in the subsequent analysis of the results; therefore, the effects of temperature and strain amplitude on the low-cycle fatigue performance of the material can be more clearly demonstrated.
3.1 Stress relaxation curve analysis
Since the experimental data for the different conditions all show stability in the stress range after 40 cycles, only the first 40 cycles are shown. First, from the change in strain amplitude at room temperature and 600 K, it can be seen from Figure 2 that the cyclic hardening of the material becomes more significant as the strain amplitude increases, while the cyclic soft hardening of the material varies at different temperatures. At 0.5% strain amplitude, the material exhibits cyclic softening at room temperature, while it remains cyclic hardening at 600 K. As the strain range increases, the cyclic hardening of the material becomes more significant, which is similar to the phenomenon found in the literature [17].
Stress amplitude evolution under strain amplitudes of 0.5–1% (cycles 1–40) at (a) 296 K and (b) 600 K.
For the variation of stress amplitude at 700 and 900 K as shown in Figure 3, there is a similar characteristic at 600 K. As the strain amplitude increases, the cyclic hardening of the material gradually increases, and the strain amplitude increases from 0.5 to 0.9% at 900 K, and the cyclic hardening amplitude increases from 71 to 379 MPa.
Stress amplitude evolution under strain amplitudes of 0.5–1% (cycles 1–40) at (a) 700 K and (b) 900 K.
In contrast to the previous trend of stress amplitude changes at lower temperatures, when the test temperature reaches 1,100 K, the material properties are substantially reduced, and the geometric softening is significantly enhanced, which is manifested as a cyclic softening in the cyclic loading test. In addition, although the material exhibits cyclic softening at all strain amplitudes, the degree of softening decreases with the increase in strain amplitude, as shown in Figure 4.
Stress amplitude evolution under strain amplitudes of 0.5–1% (cycles 1–40) at (a) 1,100 K and (b) 1,173 K.
To investigate the impact of temperature on the cyclic properties of the material, we analyze the alteration in stress amplitude when subjected to the same strain amplitude, as shown in Figure 5. It can be found that as the temperature increases, the cyclic hardening characteristics of the material at the lower strain amplitude of 0.5% gradually weaken with the increase in temperature, approaching the level at 1,100 K and showing obvious cyclic softening at 1,173 K. Compared to the 0.5% strain amplitude, the cyclic softening of the material at 1,173 K is reduced at 0.7% strain amplitude.
Stress amplitude evolution of 600–1,173 K% (cycles 1–40) at strain amplitudes of (a) 0.5% and (b) 0.7%.
3.2 Analysis of σ–ε curves and fatigue σ–N curves
Figure 6 shows the stable hysteresis curves obtained at different temperatures with a strain amplitude of 0.009, along with the repeated test results at 600 K with the same strain amplitude.
Stable hysteresis curves under different conditions. (a) Hysteresis curves at 0.009 strain amplitude at different temperatures. (b) Repeated test hysteresis curves with 0.009 strain amplitude at 600 K.
From Figure 6(a), it can be seen that the peak stress is 959 MPa at 296 K. When the temperature reaches 1,100 K, the peak stress decreases to 645 MPa, and the peak stress further decreases to 463 MPa at 1,173 K. Hence, it is evident that peak stress decreases with an increase in temperature. The hysteresis loop area increases with the intensification of the dissipated energy. As shown in Figure 6(b), there is a significant difference in the hysteresis loop area under the same strain amplitude and temperature conditions and is caused by the dispersion of the material itself.
The σ–ε curves and the fatigue σ–N curves at different temperatures are compared in Figure 7, respectively. The σ–ε curves show that the stress amplitude at equal strain amplitude decreases with increasing temperature, while the hysteresis loop area increases, indicating that the dissipated energy increases significantly.
(a) σ–ε curves and (b) fatigue σ–N curves at different temperatures.
According to the σ–N curve, the relationship between stress and life is almost linear. The position of the linear relationship decreases rapidly with the increase of temperature.
4 Conclusion
The low-cycle fatigue properties of materials at multiple temperature points and strain amplitudes can be summarized as follows:
Unlike the existing studies that are limited to a certain temperature point, this study investigates the fatigue properties at different strain levels of 0.5, 0.7, 0.9, and 1%, and fatigue tests are conducted at six temperatures ranging from room temperature to 1,173 K. Fatigue σ–N curves of the material are obtained.
When the temperature is in the range of 600–900 K, the cyclic hardening phenomenon of the material enhances with an increase of the strain amplitude. The amplitude of cyclic hardening increases from 71 to 379 MPa at 900 K, while the strain amplitude increases from 0.5 to 0.9%. This trend suggests that by optimizing the strain amplitude during the design process, it is possible to prolong the service life of a component while maintaining its performance.
The fatigue properties of GH4586 show significant changes with increasing temperature. In the temperature range of 600–900 K, the cyclic hardening phenomenon of the material increases with increasing strain magnitude, while above 1,100 K, the geometrical softening of the material is significantly enhanced and manifests itself as cyclic softening. These findings are critical for the consideration of temperature factors when designing rocket motor components, especially those operating in high-temperature environments.
As the temperature increases, the stress amplitude under the equivalent strain amplitude decreases while the hysteresis loop area increases, indicating a significant increase in the dissipated energy. The relationship between stress and life is close to linear, while the position of the linear relationship decreases significantly with increasing temperature.
The results of this study provide direct guidance for GH4586 in the design of reusable rocket engine turbines. For example, below 900 K, the component life can be significantly extended by controlling the strain amplitude in the range of 0.5–0.9%, while above 1,100 K, a combination of surface-coating techniques is required to inhibit geometrical softening. Future research could explore the effect of adding rare earth elements (e.g., La, Ce) on high-temperature stability, or using gradient material design to optimize thermomechanical properties.
In view of the softening phenomenon of GH4586 at high temperatures, future research could explore the adjustment of the alloy composition or surface treatment techniques to improve its stability and durability in high-temperature environments.
-
Funding information: Authors state no funding involved.
-
Author contributions: Yixin Ma: overall design of the study, development of the experimental protocol, data analysis, and paper writing. Bingyang Liu: experimental design and preparation of the test samples, assisted in the low-cycle fatigue test, and performed the preliminary analysis of the experimental data. Wei Wang: operation and maintenance of the experimental equipment to ensure the accuracy and safety of the experimental process and collection and processing of experimental data. Ping Jin: discussion and optimization of the experimental scheme, analysis of the experimental results, and professional technical advice. Hui Jin: statistical analysis of the experimental data, writing, and revision of the paper, and optimized the logical structure and editing. Guobiao Cai: research background and literature review, theoretical support for the study, and discussion and analysis of the experimental results. All authors have accepted responsibility for the entire content of this manuscript and approved its submission.
-
Conflict of interest: Authors state no conflict of interest.
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Data availability statement: The datasets generated during and/or analyzed during the current study are available from the corresponding author on reasonable request.
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This work is licensed under the Creative Commons Attribution 4.0 International License.
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- Fault diagnosis of agricultural sprinkler irrigation machinery equipment based on machine vision
- Closure technology of large span steel truss arch bridge with temporarily fixed edge supports
- Intelligent accounting question-answering robot based on a large language model and knowledge graph
- Analysis of manufacturing and retailer blockchain decision based on resource recyclability
- Flexible manufacturing workshop mechanical processing and product scheduling algorithm based on MES
- Exploration of indoor environment perception and design model based on virtual reality technology
- Tennis automatic ball-picking robot based on image object detection and positioning technology
- A new CNN deep learning model for computer-intelligent color matching
- Design of AR-based general computer technology experiment demonstration platform
- Indoor environment monitoring method based on the fusion of audio recognition and video patrol features
- Health condition prediction method of the computer numerical control machine tool parts by ensembling digital twins and improved LSTM networks
- Establishment of a green degree evaluation model for wall materials based on lifecycle
- Quantitative evaluation of college music teaching pronunciation based on nonlinear feature extraction
- Multi-index nonlinear robust virtual synchronous generator control method for microgrid inverters
- Manufacturing engineering production line scheduling management technology integrating availability constraints and heuristic rules
- Analysis of digital intelligent financial audit system based on improved BiLSTM neural network
- Attention community discovery model applied to complex network information analysis
- A neural collaborative filtering recommendation algorithm based on attention mechanism and contrastive learning
- Rehabilitation training method for motor dysfunction based on video stream matching
- Research on façade design for cold-region buildings based on artificial neural networks and parametric modeling techniques
- Intelligent implementation of muscle strain identification algorithm in Mi health exercise induced waist muscle strain
- Optimization design of urban rainwater and flood drainage system based on SWMM
- Improved GA for construction progress and cost management in construction projects
- Evaluation and prediction of SVM parameters in engineering cost based on random forest hybrid optimization
- Museum intelligent warning system based on wireless data module
- Special Issue: Nonlinear Engineering’s significance in Materials Science
- Experimental research on the degradation of chemical industrial wastewater by combined hydrodynamic cavitation based on nonlinear dynamic model
- Study on low-cycle fatigue life of nickel-based superalloy GH4586 at various temperatures
- Some results of solutions to neutral stochastic functional operator-differential equations
- Ultrasonic cavitation did not occur in high-pressure CO2 liquid
- Research on the performance of a novel type of cemented filler material for coal mine opening and filling
- Testing of recycled fine aggregate concrete’s mechanical properties using recycled fine aggregate concrete and research on technology for highway construction
- A modified fuzzy TOPSIS approach for the condition assessment of existing bridges
- Nonlinear structural and vibration analysis of straddle monorail pantograph under random excitations
- Achieving high efficiency and stability in blue OLEDs: Role of wide-gap hosts and emitter interactions
- Construction of teaching quality evaluation model of online dance teaching course based on improved PSO-BPNN
- Enhanced electrical conductivity and electromagnetic shielding properties of multi-component polymer/graphite nanocomposites prepared by solid-state shear milling
- Optimization of thermal characteristics of buried composite phase-change energy storage walls based on nonlinear engineering methods
- A higher-performance big data-based movie recommendation system
- Nonlinear impact of minimum wage on labor employment in China
- Nonlinear comprehensive evaluation method based on information entropy and discrimination optimization
- Application of numerical calculation methods in stability analysis of pile foundation under complex foundation conditions
- Research on the contribution of shale gas development and utilization in Sichuan Province to carbon peak based on the PSA process
- Characteristics of tight oil reservoirs and their impact on seepage flow from a nonlinear engineering perspective
- Nonlinear deformation decomposition and mode identification of plane structures via orthogonal theory
- Numerical simulation of damage mechanism in rock with cracks impacted by self-excited pulsed jet based on SPH-FEM coupling method: The perspective of nonlinear engineering and materials science
- Cross-scale modeling and collaborative optimization of ethanol-catalyzed coupling to produce C4 olefins: Nonlinear modeling and collaborative optimization strategies
- Special Issue: Advances in Nonlinear Dynamics and Control
- Development of a cognitive blood glucose–insulin control strategy design for a nonlinear diabetic patient model
- Big data-based optimized model of building design in the context of rural revitalization
- Multi-UAV assisted air-to-ground data collection for ground sensors with unknown positions
- Design of urban and rural elderly care public areas integrating person-environment fit theory
- Application of lossless signal transmission technology in piano timbre recognition
- Application of improved GA in optimizing rural tourism routes
- Architectural animation generation system based on AL-GAN algorithm
- Advanced sentiment analysis in online shopping: Implementing LSTM models analyzing E-commerce user sentiments
- Intelligent recommendation algorithm for piano tracks based on the CNN model
- Visualization of large-scale user association feature data based on a nonlinear dimensionality reduction method
- Low-carbon economic optimization of microgrid clusters based on an energy interaction operation strategy
- Optimization effect of video data extraction and search based on Faster-RCNN hybrid model on intelligent information systems
- Construction of image segmentation system combining TC and swarm intelligence algorithm
- Particle swarm optimization and fuzzy C-means clustering algorithm for the adhesive layer defect detection
- Optimization of student learning status by instructional intervention decision-making techniques incorporating reinforcement learning
- Fuzzy model-based stabilization control and state estimation of nonlinear systems
- Optimization of distribution network scheduling based on BA and photovoltaic uncertainty
