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laser cladded coating
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Ba CSD Konter, M. 1
Ru STDG1 Roberts, B. W. 1
Ba TGDL Lecheler, S. 1
Ru TSDMG/TSUG Chilton, Ian 1

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After having tested 8 specimen in C8140 (a matrix with two R-values, four of the samples
additionally shot-peened) it was obvious that the laser cladding of the surface with Stellit-6
reduces the high cycle fatigue strength of these specimens seriously. Shot-peening of the
cladded surfaces had no influence on the high cycle fatigue strength.
To determine a more accurate value of the high cycle fatigue strength reduction more tests
with samples (Stellit-6 coated, not shot-peened) were carried out.
The laser cladding of the specimen leads to a reduction of their high cycle fatigue strength of
38 % for R = -1, for R = 0 it is 22 % compared to uncoated St70AH counterparts.

Account : D5-0006-0015/81ME;D5-0006-0015/0102
Search Info
Plant : Descriptors : Beschichten / Coating;Ermüdung /
Fatigue;Oberflächenbehandlung / Surface
treatment
Component : test abbreviation list : HCF
Material : St70AH ; Stellit-6
ALSTOM (Switzerland) Ltd We reserve all rights in this document and in the information Release Resp.
Materials TGTM contained therein. Reproduction, use or disclosure to third
+41 56 205 31 84 parties without express authority is strictly forbidden.
www.alstom.ch FM000001/GTWM/20020415/D © ALSTOM (Switzerland) Ltd 2004
 TGTM-C8140N01

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After having tested 8 specimens in C8140 (a matrix with two R-values, four of the samples
additionally shot-peened) it was obvious that the cladding of the surface with Stellit-6
significantly reduces the high cycle fatigue strength of these specimen. Shot-peening of the
cladded surfaces had no influence on the high cycle fatigue strength.
To determine a more accurate value of the high cycle fatigue strength reduction more tests
with samples (not shot-peened) were carried out. For a statistically established determination
of the high cycle fatigue strength at least 5 specimens tested at each R-value, which broke in
the gauge length, were needed.
Due to some cladded specimens which did not break in the gauge length, but in the transition
or the thread, some tests have to be repeated.
Ian Chilton (TSDMG/TSUG, Rugby) did metallographic investigations of the samples tested
in C8140. His observations will be contained in a more general report. The bottom line is that
fatigue crack initiation occurred
i) at the surface,
ii) at the Stellite-6/St70AH interface, or
iii) sub-surface within the Stellite-6, but in a non-systematic way with respect to load ratio
or peening.
The incidence of micro-porosity within the Stellite-6 layer was clearly influential, in particular
when fatigue crack initiation was sub-surface.

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The base material of the specimens is St70AH (HZLM 600 056).
The Stellit-6 coating was applied by Praxair (Italy) with a laser cladding method onto special
blanks of the specimens (HRLM410082a, see C8140). Aerotech (Switzerland) machined the
final geometry (HRLM410082, see C8140). The final coating thickness was 0.3 mm on the
whole circumference of the gauge length.
The specimens were labelled with C8140-1 to 14.
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The HCF tests were carried out at ambient temperature on a computer controlled resonant
fatigue test machine (Testronik) using the same parameters as in the tests reported in
C8140: block length 200,000 cycles, load step increment of 2 %, constant R-value of -1
and 0.
The start stress amplitude of every test was less than 200 MPa.
The decrease of the resonance frequency was used for the determination of cracks.

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Table 1 gives an overview of the R-values, the achieved amplitudes and the position of the
fatal crack at the specimen. Table 2 summarises the number of the specimen which broke on
each of the different positions. Figure 1 and Figure 2 show the broken specimen and help to
understand the definition of the crack positions (gauge length, transition radius, thread).
Sample C8140-3 was used to adjust the coating process and is missing in this table and the
pictures.
In Figure 3 the results of all specimen-HCF-tests (also from C8140, labelled as C7718-x in
Figure 3) are collected and ordered by the R-value and the crack position. The horizontal
bars in Figure 3 illustrate the mean values with their standard deviation (see Table 3). For the

ALSTOM (Switzerland) Ltd, TGTM, CH-5401 Baden FM000001/GTWM/20020415/D Page 2 of 5

 TGTM-C8140N01

mean values of the uncoated specimens in Table 3 an average of the single test results from
C8027 and B5881 (Table 4) was calculated.
The results of the shot peened specimen tests match those of the not shot peened specimen
tests and were included in the statistical evaluation. A crack in the thread or in the transition
occurred earlier and led to lower HCF fatigue strength values. These results were not
included in the calculation of the mean values. The reason for the rupture of the specimen
outside the gauge length can not currently be explained.
The overall result of the tests and the calculations is that laser cladding of the specimen with
Stellit-6 leads to a reduction of their high cycle fatigue strength of 38 % for R = -1, for R = 0 it
is 22 % compared to uncoated St70AH counterparts.
HCF tests with uncoated and Stellit-6 coated KLA1 GT24 blades will take place to verify if the
cladding has the same effect on the high cycle fatigue strength of the component as on the
specimen.

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position of rupture
Specimen R-value σa [MPa] gauge length transition thread
radius
C8140-1 0 294.8 x
C8140-2 -1 303.5 x
C8140-4 0 266.5 x
C8140-5 -1 308.7 x
C8140-6 0 291.1 x

C8140-7 0 268.2 x
C8140-8 -1 392.6 x
C8140-9 0 223.0 x
C8140-10 0 307.2 x
C8140-11 -1 307.6 x
C8140-12 0 307.3 x
C8140-13 -1 400.1 x
C8140-14 0 327.6 x

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R-value shot peened broke in gauge broke in thread broke in
length transition
- 5 2 3
0
+ 2
- 5 2
-1
+ 2

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σa mean value [MPa] σa standard deviation [MPa]
R-value uncoated coated uncoated coated
0 398 310 2.4 9.6
-1 558 344 24 33
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