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Considerable effort is spent controlling the microstructure of superalloys that are used in fracture critical rotating structures for gas turbine engines. It is generally understood that a controlled, uniform microstructure is necessary for the best, most uniform mechanical properties. The aim of this effort was to evaluate this assumption in Waslapoy using a new approach to assess a material’s fatigue performance. Repeat fatigue tests were conducted at 538°C on two microstructural variants of this material to assess both the worst case fatigue and average fatigue properties, knowing that the lower limit fatigue life is the most important yet most materials and processes are developed on the basis of average properties. The lower limit of fatigue capability was found to be controlled by the largest grain size in the microstructure – not on the overall variation in grain size. This lower limit was also rationalized using a fracture mechanics approach wherein the shortest fatigue life was found to match the integration of the crack growth curve starting at the maximum observed grain size.

Evaluation of the Influence of Grain Structure on the Fatigue Variability of Waspaloy