Effectiveness of shot peening in suppressing fatigue cracking at non-metallic inclusions in Udimet® 720

The fatigue lives of modern powder metallurgy disk alloys can be reduced over an order of magnitude by cracking at inherent non-metallic inclusions. The objective of this work was to study the effectiveness of shot peening in suppressing LCF crack initiation and growth at surface non-metallic inclusions. Inclusions were carefully introduced at elevated levels during powder metallurgy processing of the nickel-base disk superalloy Udimet® 720. Multiple strain-controlled fatigue tests were then performed on machined specimens with and without shot peened test sections at 427 and 650 °C. The low cycle fatigue lives and failure initiation sites varied as functions of inclusion content, shot peening, and fatigue conditions. A large majority of the failures in as-machined specimens with the introduced inclusions occurred at cracks initiating from inclusions intersecting the specimen surface. These inclusions reduced fatigue life by up to 100×, when compared to lives of material without inclusions residing at specimen surface. Large inclusions produced the greatest reductions in life for tests at low strain ranges and high strain ratios. Shot peening improved life in many cases by reducing the most severe effects of inclusions.