Effect of coating-substrate microstructure on nucleation and growth of surface microcracks in a PtAl-coated Ni-based SX superalloy with sheet specimens during HCF at 900 °C

The fatigue crack initiation process accounts for the main portion of the high-cycle fatigue (HCF) life. Although coated superalloys are well-known to be prone to surface microcracks, the influence of the coating-substrate microstructure on the damage mechanism during HCF of the coated single crystal (SX) superalloys remains unclear. In the current study, HCF failure and interrupted tests were conducted at 900 °C under a low applied maximum stress on a PtAl-coated third-generation SX superalloy using sheet specimens. The HCF crack initiation was investigated by analyzing the evolution of surface microcracks and coating-substrate microstructure. The results show that the surface microcracks nucleation and growth are controlled by the initial microstructure of the coating-substrate region and the oxidation process during the HCF crack initiation stage. The rapid nucleation and growth of the surface microcracks are promoted by grain boundaries (GBs) in the coating and the interdiffusion zone (IDZ). Comparatively, the surface microcracks are blunted by oxidation in the SX substrate due to the loss of GBs, leading to a slower microcrack growth. However, the surface microcracks can gradually grow further into the substrate by repeating the processes as follows: oxidation at the crack tip, formation of γ′-depleted region due to oxidation, recrystallization at the γ′-depleted region and cracking along the GBs in the recrystallized γ′-depleted region. Subsequently, the surface microcracks, which reach the critical size, propagate along the slip bands during the progressive propagation stage. This study will contribute to improve the HCF durability of the PtAl-coated SX superalloy. • The coating effect on the HCF crack initiation of coated SX superalloy with sheet specimens is studied. • The relationship between the microcrack growth rate and the coating-substrate microstructure is revealed. • The surface microcracks nucleate at grain boundaries (GBs) of the coating and grow along GBs in the IDZ. • The blunted microcracks in the substrate grow further by cracking of oxidation and recrystallized γ′-depleted region.