Combustion gas turbine components designed for application in power generation equipment are subject to periodic replacement as a result of cracking, damage, and mechanical property degeneration that render them unsafe for continued operation. In view of the significant costs associated with inspecting, servicing, and replacing damaged components, there has been much interest in developing models that not only predict service life, but also estimate the evolved state of the material. This thesis explains manifestations of microstructural damage mechanisms that facilitate fatigue crack nucleation in directionally-solidified (DS) Ni-base superalloy components exposed to elevated temperatures and high stresses. In this study, models were developed and validated for damage and life prediction using DS GTD-111 as the subject material. This material has a chemical composition and grain structure designed to withstand creep damage occurring in blades of gas-powered turbines. The service conditions in these components, which generally exceed 600C, facilitate the onset of one or more damage mechanisms related to fatigue, creep, or environment. The study was divided into an empirical phase, which consisted of experimentally simulating service conditions in fatigue specimens, and a modeling phase, which entailed numerically simulating the stress-strain response of the material. Tests have been carried out to simulate a variety of thermal, mechanical, and environmental operating conditions endured by longitudinally (L) and transversely (T) oriented DS GTD-111. In some cases, tests in extreme environments/temperatures were needed to isolate one or at most two of the mechanisms causing damage. Microstructural examinations were carried out via microscopy. A continuum crystal plasticity model was used to simulate the material behavior in the L and T orientations. The constitutive model was implemented in ABAQUS and a parameter estimation scheme was developed to obtain the material constants. A physically-based model was developed for correlating crack initiation life based on the experimental life data. Assuming a unique relationship between the damage fraction and cycle fraction with respect to cycles to crack initiation for each damage mode, total crack initiation life has been represented in terms of the individual damage components observed at the end state of crack initiation.

Ni-base superalloys are widely used in hot sections of gas turbine engines due to the high resistance to fatigue and creep at elevated temperatures. Due to the demands for improved performance and efficiency in applications of the superalloys, new and improved higher temperature alloy systems are being developed. Constitutive relations for these materials need to be formulated accordingly to predict behavior of cracks at notches in components under cyclic loading with peak dwell periods representative of gas turbine engine disk materials. Since properties are affected by microstructure at various length scales ranging from 10 nm tertiary γ' precipitates to 5-30 μm grains, hierarchical multiscale modeling is essential to address behavior at the component level. The goal of this work is to develop a framework for hierarchical multiscale modeling network that features linkage of several fine scale models to incorporate relevant microstructure attributes into the framework to improve the predictability of the constitutive model. This hierarchy of models is being developed in a collaborative research program with the Ohio State University. The fine scale models include the phase field model which addresses dislocation dissociation in the γ matrix and γ' precipitate phases, and the critical stresses from the model are used as inputs to a grain scale crystal plasticity model in a bottom-up fashion. The crystal plasticity model incorporates microstructure attributes by homogenization. A major task of the present work is to link the crystal plasticity model, informed by the phase field model, to the macroscale model and calibrate models in a top-down fashion to experimental data for a range of microstructures of the improved alloy system by implementing a hierarchical optimization scheme with a parameter clustering strategy. Another key part of the strategy to be developed in this thesis is the incorporation of polycrystal plasticity simulations to model a large range of virtual microstructures that have not been experimentally realized (processed), which append the experimentally available microstructures. Simulations of cyclic responses with dwell periods for this range of virtual (and limited experimental) polycrystalline microstructures will be used to (i) provide additional data to optimize parameter fitting for a microstructure-insensitive macroscopic internal state variable (ISV) model with thermal recovery and rate dependence relevant to the temperatures of interest, and (ii) provide input to train an artificial neural network that will associate the macroscopic ISV model parameters with microstructure attributes for this material. Such microstructure sensitive macroscopic models can then be employed in component level finite element studies to model cyclic behavior with dwell times at smooth and cracked notched specimens.

Understanding the effects of aged microstructures on the thermomechanical fatigue (TMF) properties of nickel-base (Ni-base) superalloys remains unclear. Few experimental results are currently available in this area, and of the limited results available, some promote aged microstructures as beneficial, while others as detri- mental. The importance of these aged structures arises from the fact that when components used in the hot sections of gas turbine engines remain in service for ex- tended periods of time, the local temperature and stress provides the catalyst for the evolution of the microstructure. An experimental assessment of a negative misfit directionally solidified (DS) Ni- base superalloy was undertaken to characterize the aging kinetics and understand the influence of the TMF cycle temperature extremum, temperature-load phasing, mean strain, creep-fatigue, orientation effects, and microstructure on TMF fatigue crack initiation. To determine the effects of aging on the TMF response, the as-heat- treated alloy was artificially aged to three unique microstructures identified in the aging kinetics study. The experiments revealed that not all aged microstructures are detrimental to the fatigue life behavior. Specifically, when the γ′ precipitates age in a manner to align themselves parallel to the axis of the applied stress, an increase in the fatigue life over that of the as-heat-treated microstructure is observed for out-of-phase TMF with dwells. To extend the experimental understanding of the aged microstructures into ser- vice component design and life analysis, a temperature-dependent crystal viscoplas- ticity (CVP) constitutive model is developed to capture the sensitivity of the aged microstructure through embedding additional variables associated with the current state of the γ′ particles. As a result of the adaptations, the CVP model has the ability to describe the long-term aging effects of directional coarsening relevant to the analysis industrial gas turbine hot section components.

Directionally solidified Rene 80 (DS R80) and polycrystalline Inconel 738(IN 738) Superalloys were tested in thermo-mechanical fatigue (TMF) over the temperature range of 500-900°C and plastic strain range from 0.1 to 0.8% using a DSI Gleeble thermal simulator. Thermo-mechanical testing was carried out on the parent material (baseline) in the conventional solution treated and aged condition (STA), as well as gas tungsten arc welded (GTAW) with an IN-738 filler, followed by solution treatment and ageing. Comparison of the baseline alloy microstructure with that of the welded and heat treated alloy showed that varying crack initiation mechanisms, notably oxidation by stress assisted grain boundary oxidation, grain boundary MC carbides fatigue crack initiation, fatigue crack initiation from sample surfaces, crack initiation from weld defects and creep deformation were operating, leading to different “weakest link” and failure initiation points. The observations from this study show that the repaired samples had extra crack initiation sites not present in the baseline, which accounted for their occasional poor fatigue life. These defects include lack of fusion between the weld and the base metal, fusion zone cracking, and heat affected zone microfissures.

Directionally solidified Rene 80 (DS R80) and polycrystalline Inconel 738(IN 738) Superalloys were tested in thermo-mechanical fatigue (TMF) over the temperature range of 500-900°C and plastic strain range from 0.1 to 0.8% using a DSI Gleeble thermal simulator. Thermo-mechanical testing was carried out on the parent material (baseline) in the conventional solution treated and aged condition (STA), as well as gas tungsten arc welded (GTAW) with an IN-738 filler, followed by solution treatment and ageing. Comparison of the baseline alloy microstructure with that of the welded and heat treated alloy showed that varying crack initiation mechanisms, notably oxidation by stress assisted grain boundary oxidation, grain boundary MC carbides fatigue crack initiation, fatigue crack initiation from sample surfaces, crack initiation from weld defects and creep deformation were operating, leading to different “weakest link” and failure initiation points. The observations from this study show that the repaired samples had extra crack initiation sites not present in the baseline, which accounted for their occasional poor fatigue life. These defects include lack of fusion between the weld and the base metal, fusion zone cracking, and heat affected zone microfissures.

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