Quantitative assessment of microstructural damage for interior crack initiation and high cycle fatigue life modeling.

Axially loaded cyclic tests of a nickel-based alloy were conducted at 550 °C, 630 °C and 650 °C and stress ratios of −1, −0.3 and 0.5 up to high cycle fatigue regime. Multiscale characterizations and quantitative analyses of microstructural damage were carried out to illustrate the physics and mechanics of interior microstructure induced fatigue strength degradation and cracking. Results showed that the fatigue strength increased with the decreases of twin spacing, the size and aspect ratio of carbide, and γ′ phase size. Twin collapse due to slip band-twin interaction was found for the first time and confirmed as a form of crack initiation process, followed by short crack growth forming facets with significant contribution from shear stress. A new mechanistic fatigue life model of interior microstructure induced cracking was established with sound agreement with experimental data. All these combined into a design-manufacturing integrated approach which are capable of ensuring the safe operation and maintenance of service structures in long-life regime. • A shorter twin spacing, a reduced size and aspect ratio of carbide, and a smaller γ′ phase size were found beneficial for higher fatigue strength. • Slip bands-twin interaction induced twin collapse was found for the first time, which was the first step to interior facet induced cracking. • Dislocation slip, the size and location of facet was combined into a fatigue life model to evaluate interior facet induced fatigue failure. • A design-manufacturing integrated approach to anti-fatigue for long-life service structures was established. [ABSTRACT FROM AUTHOR]