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A recently published study of high temperature nitridation of iron chromium aluminum alloys (FeCrAl) at 900°C in N2–H2 has redundantly shown the formation of locally confined corrosion pockets reaching several microns into the alloy. These nitrided pockets form underneath chromia islands laterally surrounded by the otherwise protective alumina scale. Chromia renders a nitrogen‐permeable defect under the given conditions and the presence of aluminum in the alloy. In light of these findings on FeCrAl, a focused ion beam–scanning electron microscope tomography study has been undertaken on an equally nitrided FeNiCrAl sample to characterize its nitridation corrosion features chemically and morphologically. The alloy is strengthened by a high number of chromium carbide precipitates, which are also preferential chromia formation sites. Besides the confirmation of the complete encapsulation of the corrosion pocket from the alloy by a closed and dense aluminum nitride rim, very large voids have been found in the said pockets. Furthermore, metallic particles comprising nickel and iron are deposited on top of the outer oxide scale above such void regions.
The present study gives an overview of recent investigations dealing with the fatigue behaviour of the tempered martensitic steel 50CrMo4 (Fe-0.5wt%C-1wt%Cr) in the HCF and VHCF regime by taking into account a variation in material strength, by modifying the heat treatment parameters. The parameters for the tempering treatment were adapted to receive two material conditions with 37HRC and 57HRC, respectively. Subsequently, fatigue specimens were machined from the heat-treated bars for fatigue tests in an ultrasonic (f=20000Hz) and a resonance (f=95Hz) fatigue testing machine under fully reversed loading (R=-1) at laboratory air atmosphere. It was found that the dominant fatigue and fracture mechanisms change with increasing material strength. For 37HRC moderate-strength specimens crack initiation was shown to occur on the specimen surface within Cr depleted bands (segregation bands) as the dominant fatigue damage mechanism. Contrary to that, only internal crack initiation at non-metallic inclusions was observed for the high strength 57HRC condition. Furthermore, the completely different crack initiation mechanisms of the two heat treatment conditions were assessed by applying the Murakami approach relating the fatigue limit with the size of non-metallic inclusions.