ECCI/EBSD and TEM analysis of plastic fatigue damage accumulation responsible for fatigue crack initiation and propagation in VHCF of duplex stainless steels

Fatigue test data of duplex stainless steel grades, LDX 2101 and 2304 SRG, in the Very High Cycle Fatigue (VHCF) regime is presented. Fatigue testing was conducted using ultrasonic fatigue test equipment operating at 20 kHz under fully reversed tension-compression load condition. Scanning Electron Microscope (SEM) analysis of the fracture surfaces and external surfaces of failed specimens was conducted. Electron Channelling Contrast Imaging (ECCI) and Electron Back Scattered Diffraction (EBSD) studies of the axially cut surface of the failed specimens was done to analyse the accumulation of plastic fatigue damage and fatigue crack growth in the grains adjacent to the external surface and crack initiation site. Transmission Electron Microscope (TEM) analysis of thin foils cut from failed specimens of LDX 2101 was carried out to examine the effect of fatigue loading on dislocation structure. SEM studies of the Crystallographic Growth Region (CGR) showed features like grain boundaries and fatigue striations on the fracture surfaces. SEM analysis of the external surfaces of fatigue loaded specimens showed inhomogeneous accumulation of plastic fatigue damage. ECCI/EBSD analysis showed Persistent Slip Bands (PSBs) in ferrite grains in LDX 2101 grade but no PSBs were observed in any grains of 2304 SRG specimens. The barrier effect of grain and phase boundaries on short fatigue crack propagation was observed. TEM analysis of thin foils cut from the failed specimens of LDX 2101 showed stacking faults in austenite grains and they were seen to stop at the grain and phase boundaries.