Crystal plasticity simulation of the effect of grain size on the fatigue behavior of polycrystalline Inconel 718

TL;DR

This study develops a microstructure-based crystal plasticity model to analyze how grain size influences the fatigue life of Inconel 718, showing good agreement with experimental data across different strain ranges.

Contribution

The paper introduces a novel crystal plasticity model incorporating grain size effects to predict fatigue behavior in Inconel 718, validated by experimental results.

Findings

Grain size affects fatigue life at low strain ranges.

Model accurately predicts fatigue crack initiation cycles.

No significant grain size effect at high cyclic strain ranges.

Abstract

A microstructure-based model that accounts for the effect of grain size has been developed to study the effect of grain size on the fatigue life of Inconel 718 alloys. The fatigue behavior of two alloys with different grain size was determined by means of uniaxial cyclic deformation tests under fully-reversed deformation ($R_\varepsilon$ = -1) at 400$^\circ$C in the low cycle fatigue regime. The model was based in the determination of the fatigue indicator parameter (based on the local crystallographic strain energy dissipated per cycle) by means of computational homogenization of a representative volume element of the microstructure. The mechanical response of the single crystal within the polycrystal was modelled through a phenomenological crystal plasticity model which was modified to account for the effect of grain size on the monotonic and cyclic hardening/softening mechanisms. The microstructure-based crack initiation model parameters were calibrated from the experimental tests of the material with fine grain size. The results of the fatigue simulations were in good agreement with the experimental results in terms of the cyclic stress-strain curves and of the number of cycles for fatigue crack initiation. The model did not show any grain size effect on the fatigue life for the largest cyclic strain ranges while the predicted fatigue life predicted was considerably longer in the case of the microstructure with fine grain size for the lowest strain ranges, in quantitative agreement with experimental data. These differences were attributed to changes in the deformation modes between homogeneous plastic deformation at large cyclic strain ranges and localized plasticity in a few grains at low cyclic strain ranges.