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Gustafsson, David
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Publications (10 of 16) Show all publications
Palmert, F., Moverare, J. & Gustafsson, D. (2019). Thermomechanical fatigue crack growth in a single crystal nickel base superalloy. International Journal of Fatigue, 122, 184-198
Open this publication in new window or tab >>Thermomechanical fatigue crack growth in a single crystal nickel base superalloy
2019 (English)In: International Journal of Fatigue, ISSN 0142-1123, E-ISSN 1879-3452, Vol. 122, p. 184-198Article in journal (Refereed) Published
Abstract [en]

Thermomechanical fatigue crack growth in a single crystal nickel base superalloy was studied. Tests were performed on single edge notched specimens, using in phase and out of phase thermomechanical fatigue cycling with temperature ranges of 100-750°C and 100-850°C and hold times at maximum temperature ranging from 10s to 6h. Isothermal testing at 100°C, 750°C and 850°C was also performed using the same test setup. A compliance-based method is proposed to experimentally evaluate the crack opening stress and thereby estimate the effective stress intensity factor range ΔKeff for both isothermal and nonisothermal conditions. For in phase thermomechanical fatigue, the crack growth rate is increased if a hold time is applied at the maximum temperature. By using the compliance-based crack opening evaluation, this increase in crack growth rate was explained by an increase in the effective stress intensity factor range which accelerated the cycle dependent crack growth. No significant difference in crack growth rate vs ΔKeff was observed between in phase thermomechanical fatigue tests and isothermal tests at the maximum temperature. For out of phase thermomechanical fatigue, the crack growth rate was insensitive to the maximum temperature and also to the length of hold time at maximum temperature. The crack growth rate vs ΔKeff during out of phase thermomechanical fatigue was significantly higher than during isothermal fatigue at the minimum temperature, even though the advancement of the crack presumably occurs at the same temperature. Dissolution of γ′ precipitates and recrystallization at the crack tip during out of phase thermomechanical fatigue is suggested as a likely explanation for this difference in crack growth rate.

Place, publisher, year, edition, pages
Elsevier, 2019
Keywords
single crystal superalloy, thermomechanical fatigue, crack growth, crack closure
National Category
Materials Engineering Applied Mechanics Manufacturing, Surface and Joining Technology Metallurgy and Metallic Materials Infrastructure Engineering
Identifiers
urn:nbn:se:liu:diva-154074 (URN)10.1016/j.ijfatigue.2019.01.014 (DOI)000462110100017 ()
Note

Funding agencies: Siemens Industrial Turbomachinery AB in Finspang, Sweden; Swedish Energy Agency, via the Research Consortium of Materials Technology for Thermal Energy Processes [KME-702]

Available from: 2019-01-28 Created: 2019-01-28 Last updated: 2019-04-08
Chen, Z., Zhou, J., Peng, R. L., M'Saoubi, R., Gustafsson, D., Palmert, F. & Moverare, J. (2018). Plastic Deformation and Residual Stress in High Speed Turning of AD730™ Nickel-based Superalloy with PCBN and WC Tools. In: Procedia CIRP 71 (2018) pp 440-445: . Paper presented at The 4th CIRP Conference on Surface Integrity, 11th-13th July, Tianjin, China (pp. 440-445). Elsevier, 71
Open this publication in new window or tab >>Plastic Deformation and Residual Stress in High Speed Turning of AD730™ Nickel-based Superalloy with PCBN and WC Tools
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2018 (English)In: Procedia CIRP 71 (2018) pp 440-445, Elsevier, 2018, Vol. 71, p. 440-445Conference paper, Published paper (Refereed)
Abstract [en]

A higher gas turbine efficiency can be achieved by increasing the operating temperature in hot sections. AD730™ is a recently-developed wrought/cast nickel-based superalloy which can maintain excellent mechanical properties above 700 ℃. However, machining of AD730™ could be a difficult task like other nickel-based superalloys. Therefore, studies are needed with respect to the machinability of this new alloy.

In this paper, high-speed turning was performed on AD730™ using polycrystalline cubic boron nitride (PCBN) tools and coated tungsten carbide (WC) tools at varied cutting speeds. The surface integrity was assessed in two important aspects, i.e., surface and sub-surface plastic deformation and residual stresses. The PCBN tools generally showed better performance compared with the WC tools since it led to reduced machining time without largely compromising the surface integrity achieved. The optimal cutting speed was identified in the range of 200-250 m/min when using the PCBN tools, which gives rise to a good combination of machining efficiency and surface integrity. The further increase of the cutting speed to 300 m/min resulted in severe and deep plastic deformation. Meanwhile, a continuous white layer was formed at the machined surface. When turning with the WC tools, the increased cutting speed from 80 m/min to 100 m/min showed very little effect with respect to the plastic deformation on the machined surface. It was found that tensile residual stresses were developed on all machined surfaces no matter when the PCBN or WC tools were used, and the surface tension was generally increased with increasing cutting speed. The tensile layer might need to be modified by e.g., post-machining surface treatments such as shot peening, if taking good fatigue performance into consideration.

Place, publisher, year, edition, pages
Elsevier, 2018
Keywords
plastic deformation, residual stress, nickel-based superalloy, AD730TM, high-speed turning
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-148484 (URN)10.1016/j.procir.2018.05.051 (DOI)
Conference
The 4th CIRP Conference on Surface Integrity, 11th-13th July, Tianjin, China
Available from: 2018-06-12 Created: 2018-06-12 Last updated: 2018-07-03
Lundström, E., Simonsson, K., Gustafsson, D. & Månsson, T. (2014). A load history dependent model for fatigue crack propagation in Inconel 718 under hold time conditions. Engineering Fracture Mechanics, 118, 17-30
Open this publication in new window or tab >>A load history dependent model for fatigue crack propagation in Inconel 718 under hold time conditions
2014 (English)In: Engineering Fracture Mechanics, ISSN 0013-7944, E-ISSN 1873-7315, Vol. 118, p. 17-30Article in journal (Refereed) Published
Abstract [en]

Modelling of high temperature fatigue crack growth in Inconel 718 under the interaction of fast cyclic loading and hold times at maximum load has been conducted. A model, based on the concept of a damaged zone in front of the crack tip has been applied for three different temperatures, 550, 600 and 650 ◦C, with good agreement for both calibration and validation tests. A statistical evaluation of 22 tests in total was also conducted, which shows that the developed model gives a reasonable scatter factor at a probability of failure of 0.1 %.

Place, publisher, year, edition, pages
Elsevier, 2014
Keywords
Fatigue crack propagation, Inconel 718, Hold time effects, Crack growth modelling, Statistics
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-104809 (URN)10.1016/j.engfracmech.2014.02.005 (DOI)000334819600002 ()
Available from: 2014-02-27 Created: 2014-02-27 Last updated: 2017-12-05Bibliographically approved
Lundström, E., Simonsson, K., Månsson, T. & Gustafsson, D. (2014). Modelling of fatigue crack growth in Inconel 718 under hold time conditions - application to a flight spectrum. Advanced Materials Research, 891-892, 759-764
Open this publication in new window or tab >>Modelling of fatigue crack growth in Inconel 718 under hold time conditions - application to a flight spectrum
2014 (English)In: Advanced Materials Research, ISSN 1662-8985, Vol. 891-892, p. 759-764Article in journal (Refereed) Published
Abstract [en]

Gas turbine operating cycles at high temperatures often consist of load reversals mixed with hold times; the latter occurring either as cruise for aero engines or at continuous power output for land based turbines, but also at low frequency loading conditions, e.g. slow “ramp up” of engine thrust. The hold time conditions cause the crack to grow by intergranular fracture due to material damage near the crack tip, thus rapidly increasing the crack growth rate. Since the damaged zone will affect the crack propagation rate due to cyclic loadings as well, the complete load history of a component therefore has to be considered. The crack propagation model presented in this paper is based on the damaged zone concept, and considers the history effect in the form of damaged zone build up during hold times, and subsequent destruction as the crack propagates onwards by rapidly applied load reversals. By incorporating crack closure for handling different R-values, an aero engine component spectrum is evaluated for a surface crack at 550 C. The result shows a good correlation to model simulation, despite the complexity of the load spectrum.

Place, publisher, year, edition, pages
Trans Tech Publications Inc., 2014
Keywords
Fatigue crack propagation, Inconel 718, Hold time effects, Crack growth modelling
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-104812 (URN)10.4028/www.scientific.net/AMR.891-892.759 (DOI)000337767700118 ()
Available from: 2014-02-27 Created: 2014-02-27 Last updated: 2016-05-18Bibliographically approved
Gustafsson, D. & Lundström, E. (2013). Correction: Corrigendum to High temperature fatigue crack growth behaviour of Inconel 718 under hold time and overload conditions [Int. J. Fatigue 48 (2013) 178–186]. International Journal of Fatigue, 52, 157-157
Open this publication in new window or tab >>Correction: Corrigendum to High temperature fatigue crack growth behaviour of Inconel 718 under hold time and overload conditions [Int. J. Fatigue 48 (2013) 178–186]
2013 (English)In: International Journal of Fatigue, ISSN 0142-1123, E-ISSN 1879-3452, Vol. 52, p. 157-157Article in journal (Refereed) Published
Abstract [en]

n/a

Place, publisher, year, edition, pages
Elsevier, 2013
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-93953 (URN)10.1016/j.ijfatigue.2013.02.012 (DOI)000318831300016 ()
Available from: 2013-06-13 Created: 2013-06-13 Last updated: 2017-12-06Bibliographically approved
Gustafsson, D. & Lundström, E. (2013). High temperature fatigue crack growth behaviour of Inconel 718 under hold time and overload conditions. International Journal of Fatigue, 48, 178-186
Open this publication in new window or tab >>High temperature fatigue crack growth behaviour of Inconel 718 under hold time and overload conditions
2013 (English)In: International Journal of Fatigue, ISSN 0142-1123, E-ISSN 1879-3452, Vol. 48, p. 178-186Article in journal (Refereed) Published
Abstract [en]

Inconel 718 is a frequently used material for gas turbine applications at temperatures up to 650°C. For such components, the main load cycle is typically defined by the start-up and shut-down of the engine. In this main loading cycle, hold times at high temperature are commonly present in critical components. These high temperature hold times may greatly increase the fatigue crack growth rate with respect to the number of cycles unless other beneficial factors such as for example initial overloads are present. The latter can be caused by abnormal service conditions but can also occur on a more regular basis and are then typically observed in components with strong thermal transients during engine start-up. In this paper, focus has been placed on the effect of overloads on the hold time fatigue crack growth behaviour and its subsequent description. More specifically, crack propagation in Inconel 718 has been studied at the temperatures 550°C and 650°C with and without an overload at the start of the cycle. The effect of initial overloads was found to be substantial. A simple model for describing the effect of these loading conditions has also been developed based on the concept of the damaged zone, present around the crack tip. Irregular crack fronts and unbroken ligaments left on the fracture surfaces seen in complementary microscopy studies seem to support this approach. Furthermore, the stress state in front of a crack tip in a 2D model was investigated both with and without an initial overload. The results were related to the observed crack growth retardation behaviour found in the material testing.

Place, publisher, year, edition, pages
Elsevier, 2013
Keywords
Nickel-base superalloys, fatigue crack propagation, Inconel 718, hold times, grain boundary embrittlement, crack propagation modelling, Finite Element modelling
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-85931 (URN)10.1016/j.ijfatigue.2012.10.018 (DOI)000315617500020 ()
Available from: 2013-03-13 Created: 2012-12-03 Last updated: 2017-12-07Bibliographically approved
Gustafsson, D. (2013). High temperature fatigue crack propagation behaviour of Inconel 718. (Doctoral dissertation). Linköping: Linköping University Electronic Press
Open this publication in new window or tab >>High temperature fatigue crack propagation behaviour of Inconel 718
2013 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The overall objective of this work has been to develop and evaluate tools for designing against fatigue in gas turbine applications, with special focus on the nickel-based superalloy Inconel 718. The fatigue crack propagation behaviour under high temperature hold times has been studied. Firstly, the main fatigue crack propagation phenomena have been investigated with the aim of setting up a basis for fatigue crack propagation modelling. Secondly, modelling of the observed behaviour has been performed. Finally, the constitutive behaviour of the material has been studied, where focus has been placed on trying to describe the mean stress relaxation and initial softening of the material under intermediate temperatures.

This thesis is divided into two parts. The first part describes the general framework, including basic observed fatigue crack propagation behaviour of the material when subjected to hold times at high temperature as well as a background for the constitutive modelling of mean stress relaxation. This framework is then used in the second part, which consists of the seven included papers.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2013. p. 37
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 1487
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-85934 (URN)978-91-7519-750-0 (ISBN)
Public defence
2013-02-01, C3, Hus C, Campus Valla, Linköpings universitet, Linköping, 10:15 (English)
Opponent
Supervisors
Available from: 2012-12-03 Created: 2012-12-03 Last updated: 2019-12-03Bibliographically approved
Gustafsson, D., Lundström, E. & Simonsson, K. (2013). Modelling of high temperature fatigue crack growth in Inconel 718 under hold time conditions. International Journal of Fatigue, 52, 124-130
Open this publication in new window or tab >>Modelling of high temperature fatigue crack growth in Inconel 718 under hold time conditions
2013 (English)In: International Journal of Fatigue, ISSN 0142-1123, E-ISSN 1879-3452, Vol. 52, p. 124-130Article in journal (Refereed) Published
Abstract [en]

Inconel 718 is a frequently used material for gas turbine applications at temperatures up to 650 °C. The main load cycle for such components is typically defined by the start-up and shut-down of the engine. It generally includes hold times at high temperatures, which have been found to have a potential for greatly increasing the fatigue crack growth rate with respect to the number of load cycles. However, these effects may be totally or partly cancelled by other load features, such as overloads or blocks of continuous cyclic loading, and the actual crack propagation rate will therefore depend on the totality of features encompassed by the load cycle. It has previously been shown that the increased crack growth rate found in hold time experiments can be associated with a damage evolution, where the latter is not only responsible for the rapid intergranular crack propagation during the actual hold times, but also for the increased crack growth during the load reversals. In this paper, modelling of the hold time fatigue crack growth behaviour of Inconel 718 has been carried out, using the concept of a damaged zone as the basis for the treatment. With this conceptually simple and partly novel approach, it is shown that good agreement with experimental results can be found.

Place, publisher, year, edition, pages
Elsevier, 2013
Keywords
Nickel-base superalloys, fatigue crack propagation, Inconel 718, hold times, grain boundary embrittlement, crack propagation modelling
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-85933 (URN)10.1016/j.ijfatigue.2013.03.004 (DOI)000318831300013 ()
Available from: 2012-12-03 Created: 2012-12-03 Last updated: 2017-12-07Bibliographically approved
Leidermark, D., Aspenberg, D., Gustafsson, D., Moverare, J. & Simonsson, K. (2012). The effect of random grain distributions on fatigue crack initiation in a notched coarse grained superalloy specimen. Computational materials science, 51(1), 273-280
Open this publication in new window or tab >>The effect of random grain distributions on fatigue crack initiation in a notched coarse grained superalloy specimen
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2012 (English)In: Computational materials science, ISSN 0927-0256, E-ISSN 1879-0801, Vol. 51, no 1, p. 273-280Article in journal (Refereed) Published
Abstract [en]

Coarse grained superalloys are of large interest in high temperature applications, and can be found in e.g.gas turbine components, where great care must be given with respect to high temperature fatigue. Due tothe large grain size, the material behaviour at e.g. sharp notches cannot be considered homogeneous. As aconsequence, the fatigue behaviour is likely to expose a large variation. In order to numerically investigatethis variation, a Monte Carlo analysis has been carried out by 100 FE-simulations of notched specimens,where placements and orientations of the grains were randomised. Furthermore, each grain wasmodelled as a unique single-crystal, displaying both anisotropic elastic and plastic behaviour and tension/compression asymmetry. The effect of randomness was investigated by the obtained dispersion infatigue crack initiation life. It was concluded that the fatigue life behaviour of coarse grained nickel-basesuperalloys may show a considerable variation, which cannot be captured by one single deterministicanalysis based on data for a homogenised material. Furthermore, the dispersion is of such a magnitudethat it needs to be taken into account in industrial applications where highly stressed coarse grainedmaterials are used.

Place, publisher, year, edition, pages
Elsevier, 2012
Keywords
Coarse grained superalloy, Fatigue crack initiation, Critical plane approach, Crystal plasticity, Monte Carlo analysis
National Category
Applied Mechanics
Identifiers
urn:nbn:se:liu:diva-72092 (URN)10.1016/j.commatsci.2011.07.054 (DOI)000296214300034 ()
Note
Funding agencies|Swedish Research Council| 60628701 |Siemens Industrial Turbomachinery AB in Sweden||Swedish Energy Agency via the Research Consortium of Materials Technology for Thermal Energy Processes| KME-502 |National Supercomputer Centre in Linkoping, Sweden||Available from: 2011-11-16 Created: 2011-11-16 Last updated: 2017-12-08Bibliographically approved
Gustafsson, D., Moverare, J., Simonsson, K., Johansson, S., Hörnqvist, M., Månsson, T. & Sjöström, S. (2011). Fatigue Crack Growth behaviour of Inconel 718 - the Concept of a Damaged Zone Caused by High Temperature Hold Times. Procedia Engineering, 10, 2821-2826
Open this publication in new window or tab >>Fatigue Crack Growth behaviour of Inconel 718 - the Concept of a Damaged Zone Caused by High Temperature Hold Times
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2011 (English)In: Procedia Engineering, ISSN 1877-7058, E-ISSN 1877-7058, Vol. 10, p. 2821-2826Article in journal (Refereed) Published
Abstract [en]

Fatigue crack growth testing of Inconel 718 has been carried out at the temperatures 550 °C and 650 °C. The tests were conducted using a mix of hold times and pure cyclic loading, referred to as block tests. From the test results, the existence of an embrittled volume or damaged zone in the vicinity of the crack tip has been revealed. It has been found that the evolution of this damaged zone can be sufficiently well described using a power law function with an exponent n = 0.25.

Place, publisher, year, edition, pages
Elsevier, 2011
Keywords
nickel base superalloys, fatigue crack propagation, Inconel 718, hold times, grain boundary embrittlement
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-70552 (URN)10.1016/j.proeng.2011.04.469 (DOI)
Available from: 2011-09-12 Created: 2011-09-12 Last updated: 2017-12-08
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