Structural material fatigue is a leading cause of failure and has motivated fatigue-resistant design to eliminate risks to human lives. Intrinsic microstructural features alter fatigue deformation mechanisms so profoundly that, essentially, fatigue properties of structural materials become deviant. With this in mind, we initiated this project to investigate the microstructural effect on fatigue behavior of potential structural high entropy alloys. With a better understanding of the effect of microstructure features on fatigue properties, the ultimate goal was to engineer the microstructure to enhance the fatigue life of structural materials. The effects of two major deformation mechanisms presented here are twinning-induced fatigue crack retardation, and transformation-induced fatigue crack retardation. The fundamental principle of both mechanisms is to delay the fatigue crack propagation rate by altering the work hardening ability locally within the crack plastic zone. In ultrafine grained triplex Al0.3CoCrFeNi, nano-sized deformation twins were observed during cyclic loading in FCC matrix due to low stacking fault energy (SFE). The work-hardening ability of the material near the crack was sustained with the formation of twins according to Considere's criteria.
Further, due to the ultrafine-grained (UFG) nature of the material, fatigue runout stress was enhanced. In a coarse-grained, dual-phase high entropy alloy, persistent slip bands formed in FCC matrix during cyclic loading due mainly to the slight composition change that affects the SFE in the FCC matrix and eventually alters the deformation mechanism. Another way known to alter an alloy's work hardening (WH) ability is transformation-induced plasticity (TRIP). In some alloys, phase transformation happens due to strain localization, which alters the work-hardening ability.
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In a fine-grained, dual-phase metastable high entropy alloy, gamma (f.c.c.) to epsilon (h.c.p.) transformation occurred in the plastic zone that was induced from cracks. Thus, we designed a Cu-containing FeMnCoCrSi high entropy alloy that exhibited a normalized fatigue ratio of ~ 0.62 UTS (ultimate tensile strength). Our design approach was based on (a) engineering the gamma phase stability to attain sustained work hardening through delayed gamma (f.c.c.) to epsilon (h.c.p.) transformation to hinder fatigue crack propagation, (b) incorporating an ultrafine-grained microstructure to delay crack initiation, and (c) forming deformation twins to reduce the crack propagation rate. We verified that a UFG gamma dominant microstructure could provide opportunities for exceptional fatigue resistance, as sustained WH activity strengthened the material locally in the crack plastic zone, thereby validating our expectation that the combination of UFG and TRIP is a path to design the next generation of fatigue-resistant alloys.
