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<p>To gain a deeper understanding of how grit wear influences surface characteristics after polishing and to provide more accurate guidance for improving the fatigue performance of high-temperature alloys, this study investigates the effect of abrasive cloth flap wheel (ACFW) wear on polished GH4169G specimens using experimental characterisation and crystal-plasticity finite-element modelling to elucidate the relationship between abrasive wear, surface integrity, and fatigue performance. The results show that surface roughness increases from 0.21&#xa0;μm for the early ACFW to 0.51&#xa0;μm for the ultimate ACFW, and progressive ACFW wear leads to a gradual increase in both surface hardness and hardened layer depth. After polishing with the ultimate ACFW, a pronounced hardened layer forms, with hardness increasing from 476 HV for the new ACFW to 504 HV and the hardened layer depth increasing from 26&#xa0;μm to 62&#xa0;μm. The maximum residual stresses for the new ACFW, early ACFW, intermediate ACFW, and ultimate ACFW are − 315&#xa0;MPa, − 392&#xa0;MPa, − 258&#xa0;MPa, and − 175&#xa0;MPa, respectively. The specimen polished with the early ACFW exhibits the longest fatigue life of 44,688 cycles, whereas the specimen polished with the ultimate ACFW shows the shortest fatigue life of 8,326 cycles. The quality of the polished surface governs the number of fatigue crack initiation sites, while grain refinement and residual stress influence both the locations of crack initiation and the crack propagation rate. As ACFW wear becomes more severe, the number of crack initiation sites increases markedly and crack propagation behaviour shifts from deceleration to acceleration. Furthermore, the crack initiation location shifts from approximately 15&#xa0;μm beneath the surface for the early ACFW to much closer to the polished surface for the ultimate ACFW. Overall, this study provides valuable guidance for optimising abrasive tool wear mechanisms and enhancing the fatigue life of nickel-based alloys.</p>

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Influence of surface integrity induced by abrasive tool wear on fatigue performance in polished Ni-based superalloy GH4169G

  • 期刊论文

  • 发表日期：

    2026年4月27日

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  • Rui Yang,
  • Xiaojun Lin

摘要

To gain a deeper understanding of how grit wear influences surface characteristics after polishing and to provide more accurate guidance for improving the fatigue performance of high-temperature alloys, this study investigates the effect of abrasive cloth flap wheel (ACFW) wear on polished GH4169G specimens using experimental characterisation and crystal-plasticity finite-element modelling to elucidate the relationship between abrasive wear, surface integrity, and fatigue performance. The results show that surface roughness increases from 0.21 μm for the early ACFW to 0.51 μm for the ultimate ACFW, and progressive ACFW wear leads to a gradual increase in both surface hardness and hardened layer depth. After polishing with the ultimate ACFW, a pronounced hardened layer forms, with hardness increasing from 476 HV for the new ACFW to 504 HV and the hardened layer depth increasing from 26 μm to 62 μm. The maximum residual stresses for the new ACFW, early ACFW, intermediate ACFW, and ultimate ACFW are − 315 MPa, − 392 MPa, − 258 MPa, and − 175 MPa, respectively. The specimen polished with the early ACFW exhibits the longest fatigue life of 44,688 cycles, whereas the specimen polished with the ultimate ACFW shows the shortest fatigue life of 8,326 cycles. The quality of the polished surface governs the number of fatigue crack initiation sites, while grain refinement and residual stress influence both the locations of crack initiation and the crack propagation rate. As ACFW wear becomes more severe, the number of crack initiation sites increases markedly and crack propagation behaviour shifts from deceleration to acceleration. Furthermore, the crack initiation location shifts from approximately 15 μm beneath the surface for the early ACFW to much closer to the polished surface for the ultimate ACFW. Overall, this study provides valuable guidance for optimising abrasive tool wear mechanisms and enhancing the fatigue life of nickel-based alloys.