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

Fatigue crack initiation in titanium alloys is typically accompanied by the formation of planar, faceted features on the fracture surface. In the present study, quantitative tilt fractography, electron backscatter diffraction (EBSD), and the focused ion beam (FIB) have been used to provide a direct link between facet topography and the underlying microstructure, including the crystallographic orientation. In contrast to previous studies, which have focused mainly on the α-phase crystal orientation and the spatial orientation of the facets, the present analysis concentrates on the features that lie in the plane of the facet and how they relate to the underlying constituent phases and their crystallographic orientations. In addition, due to the anisotropic deformation behavior of the three basal slip systems, the orientation of the β phase as it relates to facet crystallography was investigated for the first time. The implication of the β-phase orientation on fatigue crack initiation was discussed in terms of its effect on slip behavior in lamellar microstructures. The effect of the local crystallographic orientation on fatigue crack initiation was also investigated by studying cracks that initiated naturally in the earliest stages of growth, which were revealed by FIB milling. The results indicate that boundaries that are crystallographically suited for slip transfer tend to initiate fatigue cracks. Several observations on the effect of the crystallographic orientation on the propagation of long fatigue cracks were also reported.     

Crystallography of Fluted Fracture in Near-<Emphasis Type="Italic">α</Emphasis> Titanium Alloys

The fracture topography of two-phase titanium alloys is generally complex and reflects features of the underlying microstructure, including crystallographic orientation. This article describes the correlation between crystallographic orientation and the elongated dimples, more commonly known as flutes, that are often observed on fracture surfaces of α and near-α titanium alloys and other hcp metals. The correlations are made by employing quantitative tilt fractography and electron backscatter diffraction (EBSD).     

Orientation domains and texture in hot-dipped galvanized coatings

The crystallographic orientation of galvanized coatings (Zn-0.2Al-0.15Sb in wt pct) has been characterized by Electron-Backscattered Diffraction (EBSD) and optical microscopy. While 80 pct of the nucleation spots in the coating give rise to single-crystal Zn grains, it has been found that about 20 pct of them give rise to two or more orientation domains, each having a specific crystallographic orientation. For such “polycrystalline Zn grains,” the orientations of the domains are crystallographically related: they have a dense crystallographic direction (〈1010〉, 〈1120〉, or 〈0001〉) in common. Moreover, the crystallographic relationships are similar to those observed in snowflakes and can be partially explained by the concept of a coincidence-site lattice (CSL). The EBSD measurements were also used in order to measure quantitatively the crystallographic texture. In particular, it has been evidenced that the (0001) texture of galvanized coatings is the result of two contributions: (1) the nuclei are preferentially oriented with the basal plane parallel to the coating plane (33 pct of the grains have an angle between the basal plane and the coating plane smaller than 22.5 deg), and (2) the grains having the basal plane parallel to the coating plane grow faster (these grains represent 43 pct of the coating surface). This reinforcement of the texture during growth is in agreement with that predicted by growth models, which take into account the effect of the interfaces.     

Surface relief of α″ martensite in a Ti-Mo alloy

The surface relief of α″ martensite plates in a polycrystalline Ti-4.74 at. pct Mo alloy was studied by atomic force microscopy (AFM). The orientation of matrix grains was measured by electron backscatter diffraction (EBSD), and measured surface tilt angles were compared with calculation by the crystallographic theory of martensite transformation. The observed maximum tilt angle was close to the predicted value of 7.57 deg. The overall agreement between measured and calculated tilt angles was improved significantly by taking into account not only the inclination of habit plane to the specimen surface, but also the shear direction predicted from the theory. The tilt angle may vary with the moving direction of the interface unless the habit plane is perpendicular to the specimen surface. However, this effect was small in this transformation.     

Titanium alloy fatigue fracture facet investigation by selected area electron channeling

Flat regions (facets) found on fracture surfaces caused by initiation and propagation of fatigue cracks through the titanium alloys IMI-685 tested with and without a 5 min load dwell and Ti-11 have been examined using selected area electron channeling. The crystallographic planes of the facets have been identified as being near basal for the IMI-685 and more random for the Ti-11. None of the dwell specimens showed a pure basal facet orientation. The plastic zone size was also assessed and found to correlate approximately with stress intensity, allowing confirmation of crack initiation sites as determined by fractography. One case of beta to alpha-beta transformation crystallography is also examined. A partial channeling map for titanium is presented.     

Observations of Facet Formation in Near-<Emphasis Type="Italic">α</Emphasis> Titanium and Comments on the Role of Hydrogen

Faceted features are frequently observed on the fracture surfaces of titanium alloys that have failed by static loading, continuous cycling, dwell fatigue loading, and stress corrosion cracking (SCC). Although the facets formed under different loading conditions seem qualitatively similar, there are significant differences in the spatial and crystallographic orientations of the facets as well as subtle differences in facet surface topography. The current study compares and contrasts facets for various loading conditions (cyclic, creep, SCC, and dwell) in the Ti-8Al-1Mo-1V alloy with the primary motivation being to understand the mechanisms of crack initiation and faceted growth during dwell fatigue. The spatial and crystallographic orientations of the facets were determined using quantitative tilt fractography and electron backscatter diffraction, whereas facet topography was examined using ultra-high-resolution scanning electron microscopy. Collectively, the experimental observations suggest that hydrogen may play an important role in facet formation and accelerating small crack growth rates during dwell fatigue loading.     

Faceted fracture in beta annealed titanium alloys

To better understand the correlation between fatigue failure and prior β-grain size, in β-annealed microstructures, the morphology of fatigue fracture facets which contain more than one α platelet colony in Ti-11 and IMI-685 titanium alloys was investigated. It was found that most α/β traces on the basal fracture facets, intersect at angles approximately 50, 60 and 70 deg. These angles can be predicted by the Burgers relation that allows α platelet colonies to have a common basal plane within the same prior β-grain. This commonality promotes shear related faceted fracture through more than one colony and increases the effective colony size. The increased effective colony size can cause more fatigue crack branching and, therefore, reduces fatigue crack growth rates in β-annealed microstructures.     

Correlating Scatter in Fatigue Life with Fracture Mechanisms in Forged Ti-6242Si Alloy

Unlike the quasi-static mechanical properties, such as strength and ductility, fatigue life can vary significantly (by an order of magnitude or more) for nominally identical material and test conditions in many materials, including Ti-alloys. This makes life prediction and management more challenging for components that are subjected to cyclic loading in service. The differences in fracture mechanisms can cause the scatter in fatigue life. In this study, the fatigue fracture mechanisms were investigated in a forged near-α titanium alloy, Ti-6Al-2Sn-4Zr-2Mo-0.1Si, which had been tested under a condition that resulted in life variations by more than an order of magnitude. The crack-initiation and small crack growth processes, including their contributions to fatigue life variability, were elucidated via quantitative characterization of fatigue fracture surfaces. Combining the results from quantitative tilt fractography and electron backscatter diffraction, crystallography of crack-initiating and neighboring facets on the fracture surface was determined. Cracks initiated on the surface for both the shortest and the longest life specimens. The facet plane in the crack-initiating grain was aligned with the basal plane of a primary α grain for both the specimens. The facet planes in grains neighboring the crack-initiating grain were also closely aligned with the basal plane for the shortest life specimen, whereas the facet planes in the neighboring grains were significantly misoriented from the basal plane for the longest life specimen. The difference in the extent of cracking along the basal plane can explain the difference in fatigue life of specimens at the opposite ends of scatter band.     

On the nature and crystallographic orientation of subsurface cracks in high cycle fatigue of Ti-6Al-4V

Subsurface fatigue damage, in the form of cracking of the α phase, was observed in Ti-6A1-4V during high cycle fatigue of total hip prostheses tested in a simulated physiological test geometry and environment. The subsurface cracking was found only in the region of highest fatigue stresses and was present in a zone between 50 and 700 μm beneath the surface. The density of these cracks appeared to depend on the fabrication process used to form the part, where the direction of forging deformation strongly influenced the texture and grain morphology of the near-α bimodal microstructure. A novel scanning electron microscopy (SEM) technique, using selected area channeling patterns (SACPs) and electron channeling contrast imaging (ECCI), is described and was used to determine the crystallographic orientation of the fracture plane in the a phase. The texture resulting from the forming operation appeared to be such that the basal pole of the hcp lattice became oriented in the direction of flow. Also, the deformation substructure (in the form of dislocation subcells) influenced the formation of the subsurface cracks. Observations based on four independent fractured grains, using the channeling analysis techniques, indicated that the fracture plane for these subsurface fatigue cracks is the pyramidal plane of the hcp lattice.     

Orientation imaging microscopy studies of recrystallization in interstitial-free steel

The origin of the γ fiber recrystallization texture in interstitial-free (IF) steel developed during continuous annealing has been investigated by scanning electron microscopy (SEM) and orientation imaging microscopy (OIM). Nucleation of {111∼<uvw> oriented crystals occurs in deformation banded γ grains and therefore a comprehensive study of microstructure of cold-rolled IF steel in the sections perpendicular to the rolling and transverse directions (TDs) and the rolling plane (RP) has been carried out to understand the formation, geometry, and microstructural features of recrystallization. The RP section gave abundant evidence of orientation gradients formed in γ oriented grains that had been subject to orientation splitting to give deformation bands. These orientation gradients across a single grain are around 5 to 30 deg and this orientation difference is sufficient to form nuclei with mobile interfaces during annealing and hence to create chains of γ oriented new grains in the original hot band γ grain envelopes. A grain impingement model requiring orientation pinning is then proposed to explain how these grains, contained in deformed γ grain envelopes, grow out into their neighbors to dominate the final recrystallization texture of IF steel. The α deformed grains contain only small lattice curvatures, and therefore in-grain nucleation is rare. These grains are mostly consumed by invading γ grains toward the end of the recrystallization process.     

Orientation imaging microscopy studies of recrystallization in interstitial-free steel

The origin of the γ fiber recrystallization texture in interstitial-free (IF) steel developed during continuous annealing has been investigated by scanning electron microscopy (SEM) and orientation imaging microscopy (OIM). Nucleation of {111∼<uvw> oriented crystals occurs in deformation banded γ grains and therefore a comprehensive study of microstructure of cold-rolled IF steel in the sections perpendicular to the rolling and transverse directions (TDs) and the rolling plane (RP) has been carried out to understand the formation, geometry, and microstructural features of recrystallization. The RP section gave abundant evidence of orientation gradients formed in γ oriented grains that had been subject to orientation splitting to give deformation bands. These orientation gradients across a single grain are around 5 to 30 deg and this orientation difference is sufficient to form nuclei with mobile interfaces during annealing and hence to create chains of γ oriented new grains in the original hot band γ grain envelopes. A grain impingement model requiring orientation pinning is then proposed to explain how these grains, contained in deformed γ grain envelopes, grow out into their neighbors to dominate the final recrystallization texture of IF steel. The α deformed grains contain only small lattice curvatures, and therefore in-grain nucleation is rare. These grains are mostly consumed by invading γ grains toward the end of the recrystallization process.     

Electron microscopy study of the early stage of the martensitic transformation in a U(Ga) alloy

Transmission electron microscopy was used to study the early stages of development of the isothermal martensitic α′ platelets within the metastableβ matrix in a U-1.6 at. pct Ga alloy. Analysis of the electron diffraction patterns allowed determination of the orientation relationship (0Ī1)_β ∥ 〈001〉_α′ and [100]_β′ oriented at 12 deg with respect to [010]_α. The habit plane, as determine by trace analysis, is the (411)_β plane.     

The cracking of zinc spangles on hot-dipped galvanized steel

The cracking of zinc spangles on hot dipped galvanized sheet steel was studied under controlled conditions. It was confirmed that there are two major modes of failure—boundary cracking and intragranular basal cleavage. There are four types of surface topographiesviz “mirror-like”, “feathery”, “dimpled” and “ridged”. Of these only the last type, “ridged”, was found to have its basal planes lying at an angle to the plane of the sheet. These spangles also tended to fracture most readily when strained. Hence a relationship between surface topography, crystallographic orientation and fracture behavior has been established. The implications of these findings for paint adherence is discussed. Formerly Senior Lecturer, University of Newcastle.     

Development of crystallographic texture during high rate deformation of rolled and hot-pressed beryllium

Weakly textured hot-pressed (HP) beryllium and strongly textured hot-rolled beryllium were compressed using a split-Hopkinson pressure bar (SHPB) (strain rate ∼4500 s⁻¹) to a maximum of 20 pct plastic strain as a function of temperature. The evolution of the crystallographic texture was monitored with neutron diffraction and compared to polycrystal plasticity models for the purpose of interpretation. The macroscopic response of the material and the active deformation mechanisms were found to be highly dependent on the orientation of the load with respect to the initial texture. Specifically, twinning is inactive when loaded parallel to the strong basal fiber but accounts for 27 pct of the plastic strain when loaded transverse to the basal fiber. In randomly textured samples, 15 pct of the plastic strain is accomplished by twinning. The role of deformation mechanisms with components out of the basal plane (i.e., twinning and pyramidal slip) is discussed.     

Observations on microstructurally sensitive fatigue crack growth in a widmanstätten Ti-6Al-4V alloy

Fatigue crack growth rates in commercial purity Ti-6A1-4V can be substantially reduced with a beta anneal from levels associated with the mill anneal, owing primarily to crystallographic crack bifurcation in the Widmanstätten packets. This microstructurally sensitive fatigue crack growth occurs when the reversed plastic zone is less than the packet size and results in a fracture surface with a faceted morphology. It appears from replica and scanning electron microscopic examination that the facets are comprised of three superposed features,viz cleavage-like river-line patterns, very fine striations and traces of slip lines (and slip-band cracks). Limited X-ray evidence suggests a facet orientation some 8 to 10 degrees off the basal plane.     

The thermoelastic martensitic transformation inβ′ Ni-Al alloys: I. Crystallography and morphology

This investigation describes a study of the crystallographic features of the thermoelastic martensitic transformation inβ′ Ni-Al alloys. Experimental measurements of the habit plane, shape strain and orientation relationship have been made, and the results are found to be in good agreement with the predictions of the Bowles-Mackenzie phenomenological theory, assuming δ = 1.000, p₂', and {110}_β', and d₂ = <110> _β'. The martensite habit plane normals are close to {2, 14, 15}_β' and are typically clustered in self-accommodating groups of four crystallographically equivalent variants centered around {011}_β' poles. The experimental shape strain is found to be exactly an invariant plane strain with the displacement direction lying ∼92 deg from the habit plane normal.     

Fracture morphology of NiAl single crystals tested in tension

The fracture surfaces of NiAl single crystals, strained to fracture in uniaxial tension at room temperature, were analyzed by scanning electron microscopy (SEM). Contrary to several previous reports, no preference for {011} cleavage was found. Occasionally, fracture facets close to {115} and {;117} planes were observed. For the <011> orientation, fracture tended to occur at a 45 deg angle to the tensile axis(i.e., in the direction of maximum shear stress). In the case of the <111> orientation, fracture facets exhibited similar angles but were, at the same time, close to {011} planes. In a <001> specimen, the fracture surface normals tended to include an angle close to 35 deg with the tensile axis. This suggests that the tensile fracture of <001> crystals could be associated with <111> {112} slip.     

Orientation and structure of planar facets on the massive phase γ m in a near-TiAl alloy

The orientation and structure of planar facets on the γ _m massive phase formed in a Ti-46.5 at. pct Al alloy have been characterized using a combination of transmission electron microscopy (TEM) and electron diffraction. The planar γ _m /α ₂ interfaces are irrational with respect to both the α ₂ matrix phase and the γ _m phase, and there is neither evidence of a rational orientation relationship across such facets, nor resolution of a linear defect structure within the interface planes in conventional electron diffraction patterns and amplitude-contrast images, respectively. However, when imaged parallel to a particular direction in the interface, these irrationally oriented interfaces are invariably parallel to the Moiré plane, which is defined by the intersection between two sets of closely-packed planes in the γ _m and α ₂ phases. The relationship is such that there is an effective continuity of these lattice planes across the interface and a one-dimensional coherency within the planar interface. This is interpreted to imply that such interface facets adopt a configuration of reduced energy and that they are not random and fully incoherent, as often described. It is suggested that these planar facets may migrate in a glissile manner normal to the interface plane by nucleation and rapid lateral movement within the interface plane of interfacial defects that have the form of Moiré ledges, which are defined by the spacing of the Moiré pattern that may be formed by overlap of the relevant crystal planes across the interface. This article is based on a presentation made at the symposium entitled “The Mechanisms of the Massive Transformation,” a part of the Fall 2000 TMS Meeting held October 16–19, 2000, in St. Louis, Missouri, under the auspices of the ASM Phase Transformations Committee.     

Studies of the orientations of fracture surfaces produced in austenitic stainless steels by stress-corrosion cracking and hydrogen embrittlement

Orientation studies have been made on several different austenitic stainless steels, using photogrammetric and electron channeling techniques. The fracture facets produced by SCC in boiling aqueous MgCl₂ (155 °C) were large and relatively flat in the case of type 310 steels, and the fracture plane was found to be at or near {100}. The transgranular stress-corrosion fractures in type 304 steels were more complex, and there was considerably more scatter in the orientation determinations. However, the orientations of the fracture facets in these steels were clearly not {100}, but fell into two distributions, one near {211} and the other near {110}. Electron diffraction studies from the fracture surfaces indicated the presence of α′ and martensites in the type 304 but not in the type 310 cases; the possibility that this was responsible for the differences in fracture planes is discussed. Studies were also made of a type 304 specimen which had failed by SCC at 289 °C. No martensitic phases were detected at the fracture surfaces in this case, and the fracture facets were large and flat, similar to those for type 310. Cleavage-like fracture surfaces were also produced in type 304 steels by hydrogen embrittlement, using both gaseous hydrogen and cathodic charging, but the facets were too small for precise orientation determination. Formerly with the Department of Metallurgy, University of Illinois at Urbana-Champaign. Formerly with the Department of Metallurgy, University of Illinois at Urbana-Champaign. Formerly Professor of Metallurgy, University of Illinois.