Improving the high cycle fatigue property of Ti6Al4V ELI alloy by optimizing the surface integrity through electric pulse combined with ultrasonic surface rolling process

doi:10.1016/j.jmst.2023.06.029

Abstract

Abstract: To improve the surface integrity and high cycle fatigue property of Ti6Al4V ELI alloy, the electric pulse has been introduced into the ultrasonic surface rolling process (USRP), which is called electric pulse-assisted ultrasonic surface rolling process (EUSRP). With the help of “electroplasticity” of the electric pulse, the thickness of the surface gradient deformation layer was about three times of the USRP specimens by adjusting the pulse current level. However, the surface hardness decreases due to the continuous effect of the pulse current and the “skin effect” during treatment. It is worth noting that the higher the applied pulse current, the more severe the softening. This paradox causes the fatigue performance of EUSRP specimens lower than that of USRP specimens. To break this paradox, the EUSRP treatment is followed by a USRP treatment. The EUSRP-2 (with a pulse current of 200 A) +USRP specimens exhibit excellent surface hardness, a gradient deformation layer thickness of about 400 µm, low surface roughness and high compressive residual compressive stress. Besides, the hardening mechanisms of the different surface strengthening specimens have been quantitatively analyzed in combination with microstructure analysis. The fatigue life of Ti6Al4V ELI alloy can be improved by about 25 times at 780 MPa using the EUSRP-2+USRP treatment, the main reason for the highest fatigue life is the deepest surface gradient layer and the deepest crack initiation site. The fatigue limit of the EUSRP-2+USRP specimens is not the highest because too much surface hardening causes compressive residual stress relaxation during cycling and the beneficial effect of compressive residual stress is eliminated.

Key words: Ti6Al4V ELI alloy, Combined surface treatment, Transmission electron microscopy, Residual stress, Fatigue performance

Pengfei Sun, Shengguan Qu, Chenfeng Duan, Xiongfeng Hu, Xiaoqiang Li. Improving the high cycle fatigue property of Ti6Al4V ELI alloy by optimizing the surface integrity through electric pulse combined with ultrasonic surface rolling process[J]. J. Mater. Sci. Technol., 2024, 170: 103-121.

References

[1] Q.Z. Chen, G.A. Thouas, Mater. Sci. Eng. R 87 (2015) 1-57.
[2] X.L. Liang, Z.Q. Liu, B. Wang, Measurement 132 (2019) 150-181.
[3] S. Ankem, H. Margolin, C. Greene, Prog. Mater. Sci. 51 (2006) 632-709.
[4] Q. Li, Y.F. Lu, Q. Luo, X.H. Yang, Y. Yang, J. Tan, Z.H. Dong, J. Dang, J.B. Li, Y. Chen, B. Jiang, S.H. Sun, F.S. Pan, J. Magnes. Alloy. 9 (2021) 1922-1941.
[5] Q. Luo, Y.L. Guo, B. Liu, Y.J. Feng, J.Y. Zhang, Q. Li, K.C. Chou, J. Mater. Sci.Technol. 44 (2020) 171-190.
[6] Y.P. Pang, D.K. Sun, Q.F. Gu, K.C. Chou, X.L. Wang, Q. Li, Cryst. Growth Des. 16 (2016) 2404-2415.
[7] G.L. Liu, C.Z. Huang, B. Zhao, W. Wang, S.F. Sun, Chin. J. Mech. Eng. 34 (2021) 118.
[8] Z.M. Wang, Y.F. Jia, X.C. Zhang, Y. Fu, C.C. Zhang, S.T. Tu, Crit. Rev. Solid State 44 (2019) 445-469.
[9] Y.G. Liu, M.Q. Li, H.J. Liu, J. Alloy. Compd. 685 (2016) 186-193.
[10] B. Xia, B. Wang, P. Zhang, C.X. Ren, Q.Q. Duan, X.W. Li, Z.F. Zhang, Int. J. Fatigue 161 (2022) 106891.
[11] H.L. Shi, D.X. Liu, Y.F. Pan, W.D. Zhao, X.H. Zhang, A.M. Ma, Y.H. Hu, W. Wang, Int. J. Fatigue 151 (2021) 106391.
[12] G. Ongtrakulkij, A. Khantachawana, K. Kondoh, Surf. Interfaces 18 (2020) 100424.
[13] C.Y. Zhang, Y.L. Dong, C. Ye, Adv. Eng. Mater. 23 (2021) 2001216.
[14] S.J. Lainé, K.M. Knowles, P.J. Doorbar, R.D. Cutts, D. Rugg, Acta Mater. 123 (2017) 350-361.
[15] X.K. Luo, N. Dang, X. Wang, Int. J. Fatigue 153 (2021) 106465.
[16] J.Z. Lu, H.F. Lu, X. Xu, J.H. Yao, J. Cai, K.Y. Luo, Int. J. Mach. Tool Manuf. 148 (2020) 103475.
[17] P. Maurel, L. Weiss, P. Bocher, T. Grosdidier, Mater. Sci. Eng. A 803 (2021) 140618.
[18] S.A. Chamgordani, R. Miresmaeili, M. Aliofkhazraei, Tribol. Int. 119 (2018) 744-752.
[19] C.X. Ren, Q. Wang, J.P. Hou, Z.J. Zhang, Z.F. Zhang, T.G. Langdon, Acta Mater. 215 (2021) 117073.
[20] C.X. Ren, D.Q.Q. Wang, Q. Wang, Y.S. Guo, Z.J. Zhang, C.W. Shao, H.J. Yang, Z.F. Zhang, Int. J. Fatigue 124 (2019) 277-287.
[21] D.Q.Q. Wang, Q. Wang, Y.K. Zhu, P. Zhang, Z.J. Zhang, C.X. Ren, X.W. Li, Z.F. Zhang, Mater. Sci. Eng. A 732 (2018) 192-204.
[22] C.S. Liu, D.X. Liu, X.H. Zhang, N. Ao, X.C. Xu, D. Liu, J. Yang, Int. J. Fatigue 125 (2019) 249-260.
[23] T. Roland, D. Retraint, K. Lu, J. Lu, Scr. Mater. 54 (2006) 1949-1954.
[24] M. John, A.M. Ralls, S.C. Dooley, A.K.V.Thazhathidathil, A.K. Perka, U.B. Kuruveri, P.L. Menezes, Appl. Sci. 11 (2021) 10986.
[25] G. Li, S.G. Qu, M.X. Xie, X.Q. Li, Surf. Coat. Technol. 316 (2017) 75-84.
[26] N. Ao, D.X. Liu, X.C. Xu, X.H. Zhang, D. Liu, Mater. Sci. Eng. A 742 (2019) 820-834.
[27] C.S. Liu, D.X. Liu, X.H. Zhang, D. Liu, A.M. Ma, N. Ao, X.C. Xu, J. Mater. Sci.Technol. 35 (2019) 1555-1562.
[28] X. Luo, X.P. Ren, Q. Jin, H.T. Qu, H.L. Hou, J. Mater. Res.Technol. 13 (2021) 1586-1598.
[29] Z. Wang, S. Huang, H.F. Lu, J.J. Liu, I.V. Alexandrov, K.Y. Luo, J.Z. Lu, Corros. Sci. 209 (2022) 110732.
[30] D. Kumar, S.N. Akhtar, A.K. Patel, J.R.K.Balani, Wear 322-323 (2015) 203-217.
[31] L.F. Wang, L.C. Zhou, L.L. Liu, W.F. He, X.L. Pan, X.F. Nie, S.H. Luo, Int. J. Fatigue 155 (2022) 106581.
[32] S.A. Montero, C. Navarro, J. Vázquez, F. Lasagni, S. Slawik, J. Domínguez, Int. J. Fatigue 154 (2022) 106536.
[33] L.C. Zhou, X.L. Pan, X.S. Shi, T.H. Du, L.F. Wang, S.H. Luo, W.F. He, P.M. Chen, Vacuum 196 (2022) 110717.
[34] W.F. Zhou, X.D. Ren, F.F. Liu, Y.P. Ren, L. Li, Metals 6 (2016) 297 (Basel).
[35] Q. Zhang, B.B. Duan, Z.Q. Zhang, J.B. Wang, C.R. Si, J. Mater. Res.Technol. 11 (2021) 1090-1099.
[36] Z.W. Pang, S.X. Wang, X.L. Yin, S.M. Yu, N. Du, Int. J. Fatigue 159 (2022) 106794.
[37] C.S. Liu, D.X. Liu, X.H. Zhang, S.M. Yu, W.D. Zhao, Materials 10 (2017) 833 (Basel).
[38] H.B. Wang, G.L. Song, G.Y. Tang, J. Alloy. Compd. 681 (2016) 146-156.
[39] Y.D. Ye, H.B. Wang, G.Y. Tang, G.L. Song, J. Mater. Eng.Perform. 27 (2018) 2394-2403.
[40] S.G. Qu, Z.J. Ren, X.F. Hu, F.Q. Lai, F.J. Sun, X.Q. Li, C. Yang, Surf. Coat. Technol. 421 (2021) 127408.
[41] R.J. Ji, H.Y. Wang, B.K. Wang, H. Jin, Y.H. Liu, W.H. Cheng, B.P. Cai, X.P. Li, Surf. Coat. Technol. 384 (2020) 125329.
[42] S.T. Zhao, R.P. Zhang, Y. Chong, X.Q. Li, A.A. Oden, E.Rothchild, D.C. Chrzan, M. Asta, J.W. Moris Jr., A.M. Minor, Nat. Mater. 20 (2021) 468-472.
[43] S. Liu, J. Zhu, X.D. Lin, X.B. Wang, G.C. Wang, Mater. Sci. Eng. A 799 (2021) 140164.
[44] Z.T. Xu, T.H. Jiang, J.H. Huang, L.F. Peng, X.M. Lai, M.W. Fu, Int. J. Mach. Tool Manuf. 175 (2022) 103871.
[45] D.W. Ao, J. Gao, X.R. Chu, S.X. Lin, J. Lin, Int. J. Solids Struct. 202 (2020) 357-367.
[46] K. Jeong, S.W. Jin, S.G. Kang, J.W. Park, H.J. Jeong, S.T. Hong, S.H. Cho, M.J. Kim, H.N. Han, Acta Mater. 232 (2022) 117925.
[47] N.B. Raicesic, S.R. Aleksic, I. Iatcheva, M. Barukcic, Compel 39 (2020) 623-635.
[48] X.C. Yuan, B. Lei, Z.Y. Li, W.D.Qi, in: Proceedings of the 17th International Symposium on Electromagnetic Launch Technology, La Jolla, CA, USA, 2014, pp. 1-6.
[49] H. Xiao, S.S. Jiang, K.F. Zhang, Y. Jia, C.C. Shi, Z. Lu, J.F. Jiang, J. Alloy. Compd. 814 (2020) 152257.
[50] J.X. Bao, W.J. Chen, J.N. Bai, J. Xu, D.B. Shan, B. Guo, Mater. Sci. Eng. A 831 (2022) 142262.
[51] C.F. Duan, S.G. Qu, X.F. Hu, S.Y. Jia, X.Q. Li, Int. J. Fatigue 158 (2022) 106733.
[52] A. Haque, J. Sherbondy, D. Warywoba, P. Hsu, S. Roy, J. Mater, Process. Technol. 299 (2022) 117391.
[53] H. Zhang, R. Chiang, H.F. Qin, Z.C. Ren, X.N. Hou, D. Lin, G.L. Doll, V.K. Vasude-van, Y.L. Dong, C. Ye, Int. J. Fatigue 103 (2017) 136-146.
[54] W. Zeng, Y. Shen, N. Zhang, X.X. Huang, J. Wang, G.Y. Tang, A.D. Shan, Scr. Mater. 66 (2012) 147-150.
[55] M.D. Yi, Z.Y. Wang, Y.J. Song, Z. Meng, Z.Q. Chen, G.C. Xiao, C.H. Xu, J. Am. Ceram.Soc. 106 (2022) 1443-1457.
[56] Y.T. Zhu, X.Z. Liao, X.L. Wu, Prog. Mater. Sci. 57 (2012) 1-62.
[57] G. Chen, Y.B. Peng, G. Zheng, Z.X. Qi, M.Z. Wang, H.C. Yu, C.L. Dong, C.T. Liu, Nat. Mater. 15 (2016) 876-881.
[58] P. Li, S.X. Li, Z.G. Wang, Z.F. Zhang, Prog. Mater. Sci. 56 (2011) 328-377.
[59] J. Schiøtz, F.D. Di Tolla, K.W. Jacobsen, Nature 391 (1998) 561-563.
[60] C.L. Wang, D.P. Yu, Z.Q. Niu, W.L. Zhou, G.Q. Chen, Z.Q. Li, X.S. Fu, Acta Mater. 200 (2020) 101-115.
[61] P. Luo, D.T.McDonald, W.Xu, S. Palanisamy, M.S. Dargusch, K. Xia, Scr. Mater. 66 (2012) 785-788.
[62] B.J. Hayes, B.W. Martin, B. Welk, S.J. Kuhr, T.K. Ales, D.A. Brice, I. Ghamarian, A.H. Baker, C.V. Haden, D.G. Harlow, H.L. Fraser, P.C. Collins, Acta Mater. 133 (2017) 120-133.
[63] P.F. Sun, P.L. Zhang, J.P. Hou, Q. Wang, Z.F. Zhang, J. Alloy. Compd. 863 (2021) 158759.
[64] Y. Cao, S. Ni, X.Z. Liao, M. Song, Y.T. Zhu, Mater. Sci. Eng. R 133 (2018) 1-59.
[65] P.C. Zhao, G.J. Yuan, R.Z. Wang, B. Guan, Y.F. Jia, X.C. Zhang, S.T. Tu, J. Mater. Sci.Technol. 83 (2021) 196-207.
[66] Z.W. Xu, A. Liu, X.S. Wang, B. Liu, M.H. Guo, Int. J. Fatigue 143 (2021) 106008.
[67] Y.X. Zhang, H.Q. Zhang, J.L. Xue, Q. Jia, Y. Wu, F. Li, W. Guo, Mater. Sci. Eng. A 865 (2023) 144363.
[68] W.Z. Zhuang, G.R. Halford, Int. J. Fatigue 23 (2001) 31-37.
[69] K.S. Chin, S. Idapalapati, A. Paradowska, M. Reid, S. Shukla, D.T.Ardi, in: S. Itoh, S. Shukla (Eds), Advanced Surface Enhancement, Springer, Singapore, 2019, pp. 182-189.
[70] S. Saalfeld, T. Oevermann, T. Niendorf, B. Scholtes, Int. J. Fatigue 118 (2019) 192-201.