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Materials Science & Engineering A 861 (2022) 144361

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Materials Science & Engineering A


journal homepage: www.elsevier.com/locate/msea

Effect of grain size on deformation and fracture of Inconel718: An in-situ


SEM-EBSD-DIC investigation
Wenjie Gao a, Junxia Lu a, **, Jianli Zhou a, Ling’en Liu a, Jin Wang b, Yuefei Zhang b, *, Ze Zhang b
a
Faculty of Materials and Manufacturing, Beijing University of Technology, Beijing, 100124, China
b
School of Materials Science and Engineering, Zhejiang University, Hangzhou, 310058, China

A R T I C L E I N F O A B S T R A C T

Keywords: The effects of grain size on tensile behavior of Inconel718 superalloy have been characterized by an in-situ
Inconel718 alloy tensile stage inside a scanning electron microscopy (SEM) combined with electron backscatter diffraction
Grain size effect (EBSD) and digital image correlation (DIC) at room temperature. The microstructure evolution and mechanical
In-situ SEM observation
properties of specimens under different heat treatments were performed and compared. The in-situ tensile test
EBSD
Tensile behavior
showed that the yield strength, ultimate tensile strength and reduction of cross section decrease with the
increasing grain size. An in-situ EBSD study showed that with increasing stress the local plastic deformation
become more inhomogeneous. An analysis combined in-situ SEM morphology evolution, DIC strain distribution
and EBSD results indicated that the grains deformed coordinately. Geometrically necessary dislocation (GND)
density depends on the grain size and the orientation of individual grains. The coordinated deformation ability
decreased with increasing grain size. The fracture morphology showed that with the increase of grain size, the
fracture mechanism transformed from the ductile transgranular fracture to the brittle intergranular-transgranular
mixed fracture.

1. Introduction service properties of polycrystalline superalloys like Inconel718, but


also guides the manufacture and form procedure.
Inconel718 is a Ni–Cr–Fe based superalloy with high mechanical The effects of grain size on mechanical properties and fracture
properties, excellent corrosion resistance and oxidation resistance at mechanism have been studied by many researchers. Lim et al. [21]
elevated temperature, which make it widely used for critical compo­ studied the grain size effect on EAZT211 alloy sheet and found that the
nents in aerospace industry field, such as turbine disks, chambers and yield strength of exhibits grain size dependence relies on Hall-Patch
fasteners [1–3]. Microstructures, including grain size distribution [4–6], relationship. Liu et al. [22] studied fracture behaviors of Inconel718
inclusions [7,8], texture and twin boundaries [9–12], strongly de­ superalloy sheet in different grain sizes under uniaxial tensile tests and
termines the deformation behavior and mechanical properties of found that the strength level was divided into different levels by a
nickel-based superalloy. Among these microstructures, grain size is an critical specimen thickness(t) to grain size(d) ratio value, besides the
important factor in both the production and application of poly­ number of dimples and micro-void on fracture surface decreased with
crystalline superalloys. One aspect is that grain refinement is a common increasing grain size. Raulea et al. [23] found that the yield strength and
method to improve the mechanical properties of superalloys [13–15], maximum load decrease with decreasing number of grains across spec­
the other one is nickel-based superalloy has been used in micro forming imen thickness. Du et al. [24] studied the effects of grain refinement on
process [16,17], for the parts or specimens in microscopic scale, their mechanical properties of Ni-based superalloy and found that the tensile
mechanical properties and fracture behavior are significantly different properties of K417G superalloy increase with decreasing grain size, and
from those in macroscopic scale, especially when the ratio between the tensile fracture mode transform from transgranular to intergranular.
specimen size and grain size is less than a certain extent [18–20]. The early study on grain size effects mainly according to mechanical
Realizing the effect of grain size on the deformation behavior and property curves and fracture morphology, in recent decades, more
fracture mechanism not only has significant influence on improving advanced investigation methods, such as EBSD and synchrotron

* Corresponding author.
** Corresponding author.
E-mail addresses: junxialv@bjut.edu.cn (J. Lu), yfzhang76@zju.edu.cn (Y. Zhang).

https://doi.org/10.1016/j.msea.2022.144361
Received 7 October 2022; Received in revised form 14 November 2022; Accepted 16 November 2022
Available online 21 November 2022
0921-5093/© 2022 Elsevier B.V. All rights reserved.
W. Gao et al. Materials Science & Engineering A 861 (2022) 144361

Table 1
Chemical compositions of IN718 alloy (wt%).
Ni Cr Fe Nb Mo Ti Al C B Co Mg Mn

53.71 17.98 18 5.41 2.90 0.92 0.46 0.02 0.34 0.27 0.002 0.06

Fig. 1. (a) In-situ tensile specimens; (b) Schematic diagram of specimens’ size.

radiation X-ray tomography were introduced to study the effects of grain


Table 2
size on deformation and fracture mechanisms of polycrystalline metals.
The applied heat treatment program for different sample (WQ: water quench,
Wei et al. [25] studied the grain size effect on deformation behavior of
FC: furnace cool, AC: air cool).
pure rhenium via EBSD and SEM analysis, he reported that non-basal
Number of heat treatment Solution Aging treatment
slip was slip and obvious transition from non-basal slip to basal
procedures treatment
slip-dominated flow occurred with decrease of grain size. Shang et al.
[26] used SEM-EBSD analysis combined with crystal plasticity modeling 1 1000◦ C/1h, 725◦ C/8h, FC at 55 ◦ C/h to 625◦ C
WQ + 625◦ C/8h, AC
to study the effects of grain size on void evolution and ductile fracture 2 1065◦ C/1h, 725◦ C/8h, FC at 55 ◦ C/h to 625◦ C
and found that coalescence of densely distributed voids dominates the WQ + 625◦ C/8h, AC
fracture initiation for the fine grain sample; for sample with coarse grain
the growth and coalescence of individual large void are critical for
fracture occurrence. Zhu et al. [18] used EBSD and in-situ synchrotron behavior and failure mechanism were discussed based on the experi­
radiation X-ray tomography studied effects of grain size on micro tensile mental results. The results are of fundamental and technical significance
deformation and fracture behaviors, the results show that the increase of to the production and application of Ni-based superalloy.
grain size induces inhomogeneous plastic deformation and the inter­
granular and transgranular fracture jointly control the fracture 2. Experimental procedures
behavior. Although EBSD is powerful in measuring lattice rotation and
misorientation distribution, it has limitation to reflect partial strain 2.1. Material preparation
evolution. As a non-contact measurement method, DIC is suitable and
reliable to measure strain localization in in-situ experiment and inves­ The turbine disk of Inconel718 alloy was used in this study. The
tigate the relationship between microstructure and plastic deformation. chemical composition (wt.%) of the superalloy are shown in Table 1. To
Although plenty of investigations of effect of grain size on mechan­ get micro-tensile specimens, the disk was wire-cut into dog-bone shaped
ical properties, deformation and fracture mechanisms have been geometry with a gage length of 1.5 mm, a gage thickness of 0.7 mm and
completed, these studies are mostly conducted by ex-situ test, in-situ a gage width of 1.5 mm as shown in Fig. 1 by electrical discharge
studies are rare. Compared with in-situ investigation, ex-situ investiga­ machining (EDM).
tion is after-effect analysis. Therefore, in-situ investigation of the grain To investigate the grain size effects on specimens’ mechanical
effect on polycrystalline metals, such as Inconel718, is of great signifi­ properties, microstructure evolution, strain distribution and fracture
cance for it could greatly help to research the deformation behavior behavior, the specimens were divided into 2 groups to subject to
under different certain load condition and to realize how the grains different heat treatment procedures shown in Table 2. Heat treatment
influence each other in real time, so that deeply understand the effect of was carried out in atmospheric environment using air furnace. After heat
grain size on superalloy over whole load deformation process. treatment, the specimens were polished with silicon abrasive papers
In the current study, the grain size effects on Inconel718 superalloy (SiC 300# to 2000#) and 0.5 μm diamond paste until mirror smooth and
were studied via in-situ SEM-EBSD-DIC. Inconel718 specimens with then etched with a mixture solution of 100 ml HCl, 100 ml C2H5OH and
different grain sizes were gained by different heat treatment. To observe 5 g CuCl2 for 1 min at room temperature to reveal the microstructure. To
the real time microstructure evolution under deformation and to reveal meet the surface requirement for EBSD, the specimens were electro­
the grain size effects on mechanical properties of specimens, a self- chemically polished in a solution of HClO4 and C2H5OH firstly with a
developed in-situ tensile stage was put into SEM chamber. In-situ voltage of 18 V at room temperature for 15 s. To generate pattern for DIC
EBSD was used to study microstructure evolution at different tensile analysis, the specimens were second-stepped electrochemically polished
conditions. DIC was used to investigate the strain localization in indi­ with a voltage of 27 V at room temperature for 5 s to generate tiny
vidual grains. After tensile test, the fracture surfaces were characterized bumps, these bumps can serve as pattern and won’t influence EBSD
by SEM. The effects of grain size on mechanical properties, deformation measurement [27].

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Fig. 2. (a, b) Schematic diagram and photo of in-situ tensile system; (c, d) Schematic diagrams and photos of in-situ EBSD system.

2.2. In-situ tensile SEM-EBSD [28] has reported detailed description of the system.
In this current study, in-situ tensile test was conducted at a load
The in-situ tensile test system consists of self-developed in-situ ten­ speed of 1 μm/s at room temperature. Before tensile, the real size of the
sile stage and TESCAN S8000 SEM, as shown in Fig. 2(a) and (b). The specimens was measured to confirm the effective cross section so that
sample was hold by clamps to let the electron beam scan its surface. The the stress could be calculated. The real time load-displacement curve
tensile stage is driven by a motor and a double screw, a multi-gear was recorded via the control system, and the tensile test could be paused
system realizes uniaxial tensile along the central axis of the specimens. at any certain deformation condition to observe the morphology of the
The three main parameters of the tensile stage are: Force sensor range specimen and take SEM image according to the curve. After image
from 0 N to 2500 N with an accuracy ±0.1%, Loading speed range from acquisition, the tensile test was resumed. After tensile test, the fracture
0 μm/s to 12 μm/s, Displacement resolution: 0.5 μm. A previous work morphologies were observed via SEM to show the fracture mechanism.

Fig. 3. (a, b) IPF maps of FG and CG specimens under different heat treatment and (c, d) their average grain size.

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Fig. 4. (a, b) SEM images of TiN and MC carbide; (c, d) elemental distribution mapping of (a) and (b).

To study the microstructure evolution, including grain orientation


evolution, slip system activation, grain boundary evolution and strain
localization of the sample under deformation in real time, a 50◦ tilted
holder was introduced into the in-situ tensile system and sample was
titled to 20◦ so that EBSD (Symmetry, Oxford) data could be collected
during the interruption, as shown in Fig. 2(c) and (d). The accelerating
voltage is 20 kV, working distance is 18 mm, scanning step is 1.5 μm.
Three EBSD mapping regions were selected for each sample and SEM
images of the same regions were taken after each EBSD scanning for DIC
analysis. The EBSD data analysis software is Aztec Crystal (Oxford).

2.3. DIC measurement

In this study the pattern for DIC analysis was generated by before
mentioned two-step electrochemically polished method. After every
EBSD scanning, the morphology of the same research area was taken
through SEM in high resolution for DIC analysis, so that we can relate
the strain localization and microstructure evolution to investigate
plastic deformation mechanisms. Images were obtained at a resolution
of 4096 × 3072 pixels. DIC analysis was performed using Nocrr open-
source MATLAB software, subset size is 30 μm, step size is 4 μm. Fig. 5. Stress-displacement curve of Inconel718 specimens under different
Based on the deformation sequence, DIC analysis provided displacement heat treatment.
field, u(X), to calculate tensile strain, εxx. Distribution of εxx represented
strain localization in the area of interest. grain size distribution of specimens, the equivalent diameter is used to
calculate the average grain size. It can be found that the average grain
3. Results size increases from 14.82 μm to 73.61 μm with increasing solution
temperature from 1000◦ C to 1065◦ C.
3.1. Microstructures A certain number of polygonal-shaped particles could be observed at
grain boundaries and inside grains, these particles show different
The initial microstructures of the fine grain (FG) and coarse grain contrast in SEM images. According to Energy Dispersive Spectroscopy
(CG) tensile specimens subjected to different heat treatment are shown (EDS) analysis as shown in Fig. 4, these particles could be confirmed to
by inverse pole figure (IPF) maps in Fig. 3. The random orientation of the be (Ti,Nb) N and MC carbides.
specimens indicating that heat treatment eliminates the texture and the
grains are equiaxed. Besides, a large number of annealing twinning
microstructures could be observed. Fig. 3(c) and (d) show the average

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Table 3 to 73.61 μm, the YS decreases by 85 MPa and UTS decreases by 273 MPa.
Mechanical properties of fine and coarse grain Inconel718 specimens. The reduction of cross section decreases from 22.72% to 13.56%.
Average grain Yield stress/ Ultimate tensile Reduction of cross
size/μm MPa stress/MPa section/% 3.3. In-situ observation of morphology evolution during tensile
14.82 1120 1463 22.72 deformation
73.61 1035 1190 13.56
The surface morphology evolution of specimens with various
average grain sizes under tensile deformation was observed via In-situ
3.2. Mechanical properties
SEM. Fig. 6 shows the whole deformation process of the sample with
average grain size of 14.82 μm. The original surface morphologies
To investigate the influence of grain size effect on microstructure
before tensile are shown in Fig. 6(a1-a3). When the stress reached 1260
evolution and mechanical properties of the samples under deformation,
MPa beyond yield point and the sample under strain hardening stage
in-situ tensile experiments were implemented. The stress-displacement
(point b1 on the red curve in Fig. 5), slip bands could be observed but
curves of specimens with different average grain size are shown in
grain boundaries didn’t change obviously as shown in Fig. 6(b1) - (b2),
Fig. 5. It should be noted that because of stress relaxation during the
which indicates that the plastic deformation is mainly accommodated by
interruption of tensile test [29], stepwise patterns at certain stage of the
slip. At this tensile stage, only single slip bands could be observed in
curves could be observed, the slight drop of value proves that the tensile
some of the grains, and crack could be observed on particles, as Fig. 6
stage is stable. The strain hardening phenomenon could be observed
(b3) shown. When the stress increased to 1446 MPa (point c1 of the red
from the curves of different specimens that the flow stress increase with
curve), the plastic deformation became stronger, the grains were obvi­
increasing deformation. The strain hardening phenomenon of FG spec­
ously elongated, and the surface of the sample became uneven. Fig. 6(c2)
imen is more obvious according to the curves. Additionally, the flow
shows that the grain boundary become curved and the contrast changes,
stress decreases with increasing average grain size.
indicating that the grains have rotated in order to coordinate the
The values of yield stress (YS), ultimate tensile stress (UTS) and
deformation so that strain has accumulated at the grain boundary.
reduction of cross section of the fine and coarse specimens are shown in
Particles cracked into pieces and voids on grain boundary could be
Table 3. It is obvious that all these values decrease with the increasing
observed as Fig. 6(c3) shown. When stress decreased to 1393 MPa from
average grain size. When the average grain size increases from 14.82 μm
higher value, the morphologies of the sample’s surface before fracture

Fig. 6. Morphology evolution of specimen with average grain size of 14.82 μm at different stress under tensile deformation: (a1-a3) 0 MPa; (b1-b3) 1260 MPa; (c1-c3)
1446 MPa; (d1-d3) 1393 MPa.

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deformation. At the same time, the carbides on the surface of the sample
cracked and voids inside grains and at grain boundaries could be
observed, as indicated by arrows in Fig. 7(c2). When the specimen was
about to crack and the stress was 1180 MPa (point d2 of the blue curve),
it could be noticed that the necking behavior of FG specimen is much
more obvious than CG specimen as Fig. 7(d1) and Fig. 6(d1) shown,
which is evidenced by the reduction of cross section, the value for FG
specimen is 22.72% and for CG specimen is 13.56%. Fig. 7(d2) shows
that the voids at grain boundary were enlarged during deformation and
propagated to transgranular crack.

3.4. Microstructure evolution during tensile deformation

The microstructural evolution of the research area and certain grains


during tensile deformation was investigated via in-situ tensile EBSD and
shown in Figs. 8 and 9. The normal direction of the sample surface is the
observation direction, and the horizontal direction(X) is the loading
direction. To investigate the influence of neighboring grains, twins were
regarded as different grains. Several certain grains were assessed in the
undeformed samples. Fig. 8(a) shows that the undeformed grains
contain uniform orientation distribution before loading. When the ten­
sile stress increased to 1127 MPa and the sample just beyond yield stage,
grain orientation rotation could be observed from the IPF map. Orien­
tation distribution in some grains became uneven and changed to
varying degrees, that is, in grains 6 and 7. At this stage most of the grains
still maintain their original orientation, such as grains 1, 3 and 5. With
plastic deformation process and increasing stress to 1175 MPa, more
grains contained uneven orientation distribution and multiple sub­
regions could be observed within grains 2, 4, 6 and 7, indicating inho­
mogeneous deformation in individual grains. The grain orientation
evolution of CG sample is shown in Fig. 9(a), which is similar to the
results of FG sample. It could be concluded that grains rotated and grain
orientation significantly varied with increasing stress. It’s notable that
large misorientation within grains tends to occur at twin boundaries or
trigeminal grain boundaries and evolved to substructure.
The lattice rotation path can be manifested by the evolution of the
Fig. 7. Morphology evolution of sample with average grain size of 73.61 μm at
grain orientation parallel to the loading direction X [30,31]. The lattice
different stress under tensile deformation: (a1, a2) 1091 MPa; (b1, b2) 1132 rotation paths of individual neighboring grains in FG sample are shown
MPa; (c1, c2) 1175 MPa; (d1, d2) 1180 MPa. in Fig. 8(b). Grains 4 and 5 are analyzed together for the similar original
orientation (misorientation around 5◦ ) and rotation behavior. Individ­
are shown in Fig. 6(d1-d3), obvious necking of the sample could be ual grains rotated continuously with increasing stress. The splash
noticed and the stress concentration caused by necking lead to the pattern indicated that misorientation was significant in grains 4, 5 and 7
initiation of long cracks. These cracks contain both intergranular and although the plastic deformation was not extreme. On the contrary, less
transgranular cracks, as Fig. 6(d3) shown. The grains were obviously misorientation appeared in grains 1, 2, 3 and 6. Different rotation
elongated, and the intergranular cracks seem to be induced by the behavior indicated inhomogeneous deformation. Fig. 9(b) shows that
extrusion of adjacent grains. In addition, most of the voids caused by similar lattice rotation behavior was also observed in CG sample, which
particle crack didn’t propagate to long cracks. With tensile continued, indicates that rotation of several individual grains has little relation with
the cracks on the surface of specimen connected each other and led to grain size. Besides, according to the classical modes proposed by Sack
the final fracture of the specimen. [32] and Taylor [33], for a single-crystal face-centered cubic (FCC)
Compared with the FG specimens, the CG specimen with average metal under plastic deformation, the orientation will rotate to a
grain size of 73.61 μm shows different features during tensile defor­ <− 112> stable position. The experimental results show that the rota­
mation as Fig. 7 shown. When the stress reached 1091 MPa (point a2 of tion paths of grains 1, 4, 5 in FG sample and grains 2, 4, 5 in CG sample
the blue curve), the specimen was beyond yield point and the surface follow the classical modes, while the rotation paths of other grains
morphology of the sample had no obvious change. But slip traces deviated from the stable position, which means for polycrystalline
belonging to different slip systems could be observed as shown in Fig. 7 metal, the orientation behavior of individual grain not only follows the
(a2), which is not observed in the FG specimen under the similar tensile classical modes but also influenced by surrounding grains and the whole
stage. At the same time, it is worth noting that, unlike the FG specimens, sample deformed coordinately.
the particles on the surface of the CG specimen did not crack at the In-situ SEM tensile test shows the multiscale morphology evolution
similar tensile stage. With stress increasing to 1132 MPa (point b2 of the of specimens at different deformation stage during the whole tensile
blue curve), as Fig. 7(b1-b2) shows, the grain boundaries became curved process. Essentially local misorientation could be used to characterized
and the surface of the specimen became uneven, density of slip bands plastic strain evolution in deformed materials [29]. The strain locali­
increased, and more multiple slip systems were activated. When stress zation of the FG and CG specimens is shown in Fig. 10. The strain
reached 1175 MPa (point c2 of the blue curve), the necking of the sample localization is characterized by kernel average misorientation (KAM)
was not obvious, the grains were elongated, and the grain boundaries analysis. KAM maps (Fig. 10(a and b)) show that with KAM value
became curved indicating that the grains have rotated to coordinate the increased continuously with increasing stress, which is consistent with
the inhomogeneous grain rotation behavior. Moreover, larger KAM

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Fig. 8. (a) Grain orientation evolution maps of FG sample subjected to different levels of stress (0 MPa, 1127 MPa, 1175 MPa). (b) Orientation evolution parallel to
the loading direction X of individual grains during tensile deformation in an IPF.

tends to accumulate near twin boundaries, trigeminal grain boundaries specimens are researched through SEM as Fig. 11 shown. Fig. 11(a1)
and subregions, which indicates that the inhomogeneous and coordi­ shows the fractography of FG specimen. It can be observed that the
nated deformation of neighboring grain caused strain localization. The fracture surface is flat and the middle of the fracture surface is covered
comparing of KAM values of FG/CG samples at different stress levels by equiaxed dimples (marked by the white dash square) and the edge is
(Fig. 10(c and d)) shows that KAM values are around 1◦ when stress is 0 covered by shallow dimples. The mixed structure of fracture surface
MPa. When stress increased, the distribution of KAM values varied and indicates that the fracture mode of FG specimen is transgranular frac­
proportion of KAM >1◦ increased, indicating increasing deformation ture. Besides, many large voids could be observed on the fracture sur­
inhomogeneity. The trend and value of KAM evolution of FG/CG sam­ face, which are caused by particles (TiN and MC carbides) as Fig. 11(a2).
ples don’t show obvious different, which means the partial area and It could be assumed that the cracking of particles is an important source
individual grains of both FG and CG samples have similar coordinate for fracture behavior. Fig. 11(a3) shows that many small voids could also
deformation trend. be observed on fracture surface, these micro-voids coalesced to form
dimples and lead to fracture [22]. For the CG specimen, the fractography
is much different from FG specimen. Fig. 11(b1) shows that the fracture
3.5. Fractographies of samples with different grain sizes
surface is uneven and covered by shallow dimples. The size of dimples
increases with increasing average grain size. Large voids caused by
To investigate the effect of grain size on fracture mechanisms in
particles crack decreased compared with FG specimen. In addition,
microscale, the morphologies of fracture surfaces of FG and CG

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Fig. 9. (a) Grain orientation evolution maps of CG sample subjected to different levels of stress (0 MPa, 1079 MPa, 1108 MPa). (b) Orientation evolution parallel to
the loading direction X of individual grains during tensile deformation in an IPF.

intergranular surfaces and cracks could be observed from the mechanism of rotation and coordinated deformation of adjacent grains
morphology, as Fig. 11(b2) and (b3) shown. Such mixed fracture char­ and the deformation inside each single grain is important to understand
acteristics reveal that the decrease of plastic deformation ability and the plastic deformation behavior of the whole specimens.
mixed trans-intergranular fracture mode of CG specimen. Fig. 12 shows the rotation and coordinated deformation of 11 adja­
cent grains of an FG specimen via in-situ EBSD experiment at different
4. Discussion stress levels (0 MPa, 1127 MPa, 1175 MPa), this research area is same
with Fig. 8. Fig. 12(a) shows the morphology evolution and activated
4.1. Mechanism of rotation and coordinated deformation of adjacent slip system of individual grains. The determination of the slip system
grains through following steps [34]: using the Euler angles of a grain to
determine the four {111} slip plane traces and thus determine which
The morphology and microstructure evolution of Inconel718 super­ plane the slip traces belong to, the slip direction is determined by
alloy specimens with various average grain sizes have been analyzed in calculating the largest Schmid factor of all the {111} <111> slip sys­
previous sections focusing on the over changes under tensile deforma­ tems. Fig. 12(b) shows the increment strain distribution via DIC analysis.
tion. However, the macroscopic changes are highly influenced by the The pattern used for DIC was generated through electrolytic polishing
joint action of individual grains. The microstructure evolution process and corrosion when preparing specimens. Fig. 12(c) shows the Schmid
shows that individual grains tend to deform coordinately. To study the factor distribution evolution and Fig. 12(d) shows the histogram of the

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Fig. 10. (a, b) KAM value maps of FG/CG samples subjected to different stress levels. (c, d) Distribution of KAM values at different stress levels in FG/CG samples.

Schmid factor value corresponding to Fig. 12(c). To conclude, individual grains deform through slip system activation
When the stress reached 1127 MPa and the specimen yielded, it can and rotation to release the stress and keep the continuity of specimen. To
be observed from the morphology that most of grains (grains 1, 3, 4, 5, 6, activate the slip system, the hard-oriented grains will continue to rotate
9, 10, 11) activated slip systems firstly and slip traces appeared on the during the deformation process to achieve a favorable orientation, while
specimen’s surface. It is worth to note that only single slip system was soft-oriented grains adjacent to them also rotate coordinately to ensure
activated in these grains except grain 6. The strain distribution map in the continuity of all the grains.
Fig. 12(b) shows that the strain among grains is heterogeneous and grain
bands are consisted with the slip traces, which indicates that at this stage 4.2. Geometrically necessary dislocation (GND) development
dislocation slip is the main plastic deformation method to release stress.
When tensile stress increased to 1175 MPa, more slip traces could be During the coordinated deformation of polycrystalline Inconel718
observed in the prior slipped grains and the strain bands became alloy, GNDs are generated to connect the inhomogeneous plastic
extremer. Slip systems in grains 2, 11, 12 activated with grain orienta­ deformation of individual grains so as to ensure the compatibility re­
tion rotation as shown in Fig. 8 (a). Besides, although no slip traces could quirements. Dislocation strengthening can influence the deformation
be observed in grains 7 and 8, large strain localization appeared in these behavior and mechanical properties of alloy, Smith et al. [35] pointed
grains. Combined with the grain orientation rotation shown in Fig. 8 and out that in FCC metals GNDs account for most dislocations so that in this
misorientation accumulated shown in Fig. 10, we could conclude that current study GND development is investigated.
grains 7 and 8 deformed coordinately with other grains through grain The GND density was calculated through EBSD data, kernel size is 9
rotation to maintain the continuity of the whole specimen instead of × 9 and the Burgers vector of Inconel718 is 0.25 nm. Fig. 13 (a) and (b)
activating slip systems. show that the GND density distribution development at different stress
The Schmid factor (SF) is often used in research to judge the diffi­ of FG and CG sample. Similar phenomenon was observed at all three
culty level of slip system activation in individual grains. The larger the areas of interest (AOI), we show the same area of previous sections for
Schmidt factor a grain has, the easier for it to activate the slip system and better comparison. It could be noticed that the GND density distribution
to deform, this kind of grain orientation is called soft orientation. The is consisted with KAM map and the GND density concentration area is
opposite situation is called hard orientation. Grains with Schmidt factor consisted with strain concentration area in DIC map, which points that
larger than 0.45 are defined as soft orientation grains. As shown in the GND concentration is generated due to local plastic deformation and
Fig. 12 (a) and (c), when stress reached 1127 MPa, most firstly slipped orientation rotation. However, in DIC map the strain band is consisted
grains have high SF and soft orientation. However, grains with low SF with slip traces, which is not observed in GND density map. It could be
(grains1, 3, 11) still activated slip systems and grain 12 with soft easily noticed that the GND density value of CG sample is much less than
orientation didn’t slip indicate that the value of Schmid factor is not the FG sample, similar trend is also observed by Littlewood et al. [36] and
only decision factor for slip system activation. When stress increased to Kundu et al. [37]. One aspect to explain such trend is that FG sample
1175 MPa, grains 2 and 13 rotated to softer orientation and activated with larger average grain size permits more free movement and wider
slip systems with coordinated rotation of neighboring grains. Fig. 12 (d) dislocation spacing to reduce GND accumulation [38]. The other
shows that before loading the percentage of soft orientation is 78%, the mechanism is that FG sample contains more grain boundaries and the
value decreased to 70% when stress reached 1175 MPa, which indicates grain boundary can serve as obstacle for dislocation movement leading
that the research area tends to a harder orientation. to dislocation accumulation near grain boundary. The evolution of GND

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Fig. 11. Comparison of fracture morphologies: (a1-a3) FG specimen; (b1-b3) CG specimen.

density in individual grains also shows difference. Fig. 13(c) shows the the grain. Previous study [39] demonstrated that in soft grain the GNDs
GND density evolution of three individual grains 1, 3 and 4. Grain 4 has will continue to move on the slip plane until reach grain boundaries, and
soft orientation and its SF is 0.48. Grain 3 is a hard grain with a 0.39 SF the GNDs will accumulate inside hard grain, which is consisted with this
value. The SF of grain 1 is between grain 1 and 4. In the soft grain 4, study. Moreover, this current study shows that for grain with “medi­
when the stress reached 1127 MPa and sample yielded, the GNDs um-orientation” like grain 1, the GNDs tend to accumulated at the sub
distributed in the whole grain. With stress increasing to 1175 MPa, most area with high orientation rotation (compared with Fig. 8). Fig. 13 (d)
of the GNDs moved and accumulated near the grain boundary. The hard shows that the average GND density of grians1, 2, 3 and the AOI of FG
grain 3, on the contrary, the GNDs didn’t show obvious accumulation and CG sample. The increasing rate of FG is larger than CG, and the
behavior during the stress increasing process. For grain 1, just like it’s SF comparison between hard and soft grains shows the same trend.
value, the GNDs evolution trend is between grain 3 and 4: the GNDs
tends to move to grain boundaries with some GNDs accumulated inside

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W. Gao et al. Materials Science & Engineering A 861 (2022) 144361

Fig. 12. Coordinate deformation of adjacent grains 1–11 subjected to different stress levels (0 MPa, 1127 MPa, 1175 MPa): (a) morphology evolution; (b) strain
evolution; (c) Schmid factor distribution evolution; (d) histograms of Schmid factor evolution.

4.3. Grain size effect on the deformation and fracture mechanism


Specimen thickness(t)
N= (1)
Grain size(d)
According to previous sections, we could know that the mechanical
properties, including flow stress, yield stress, ultimate tensile stress and In this current study, as the thickness of specimens are similar, the N
reduction of cross section decrease with the increased average grain size of different specimens decrease with increasing average grain sizes. The
of the specimens, along with different morphologies evolution indicate N of FG and CG specimens are 101 and 20. According to Keller et al.
that the grain size of the specimens influence the plastic deformation [41], when N is larger than 4, the mechanical properties depend only on
behavior. Besides, the different fractographies shows the influence of the grain size. The Hall-Petch relation was widely used to describe the
grain size on fracture mechanism. However, focusing on the micro­ grain boundary strengthening mechanism [42,43], σhp (ε) and k(ε) are
structure evolution and coordinated deformation of adjacent individual constants:
grains, the specimens with different average grain sizes show similar
behavior. It could be assumed that it is the co-acting of all the grains the σ (ε, d) = σhp (ε) + k(ε)d− 1/2
(2)
specimen contains that lead to the differences. It is important to discuss As obstcle of deformation, the fraction of grain boundaries decreases
the grain size effect on the deformation and fracture mechanism of the with increasing grain size, so that the specimens with larger average
Inconel718 superalloy during deformation. grain size have lower YS, UTS and less obvious strain hardening phe­
In many previous studies, the interactive effect of grain sizes and nomenon.According to the H–P relation, with increasing grain size, the
specimen was quantified with the ratio [20,22,40]:

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W. Gao et al. Materials Science & Engineering A 861 (2022) 144361

Fig. 13. (a, b) GND density maps of FG/CG samples subjected to different stress levels, (c) GND density evolution of individual grains 1, 3 and 4, (d) variation of
average GND density.

Fig. 14. Surface models of FG and CG specimens.

decrease of strenghten effect that leads to the decrease of the flow stress the specimens with larger average grain size have lower flow stress.
[20]. Besides grain boundary strengthening mechanism, dislocations For the differences of the fractographies, the specimens with larger
strengthening can also play an important role and be expressed by the average grain size contain less fraction of grains and boundaries. The
Bailey-Hirsh relation [44]: less grains make it more difficult for coordinated deformation. For one
aspect, less soft-oriented grains in favorable orientation make it more
Δσb = BMbGρ1∕2 (3)
difficult to release stress through slipping; for the other aspect, as dis­
cussed in section 4.1 and previous study [47], soft-oriented grains
where B is a coefficient of proportionality, ρ is dislocation density
adjacent to hard-oriented grains need to rotate coordinately to maintain
including GNDs and statistically stored dislocations, G is shear modulus
the continuity, additionally as Zheng et al. [48] stated, the fine grains
and b is Burgers vector. In this current study, the FG specimens have
are easier to rotate than coarse grain, so the CG sample contains less
much larger GND density than CG spaciemns, leading to the better
grains is more difficult to deform coordinately. And because of the grains
mechanical properties of FG specimens because of dislocations
are constrained, multi-slip is easier to be activated to release stress and
strengthening. Moreover, according to the surface grain weaken model
deformation is more inhomogeneous. Compared with CG specimens, less
[19], with N decreased, the fraction of grains at the surface of the
multiple slip systems are activated in FG specimens because of more
specimen increased, as Fig. 14 shown. As the surface grains have less
uniform deformation. According to research of Shang et al. [26], shear
limitation to deformation through slip or rotation [20,45], which is
stress concentrates at some parts of the boundaries, in these regions
different from the inner grains, the surface grains have less flow stress as
dimples and micro-voids tends to coalesce to form bigger voids rather
illustrated by Miyazaki et al. [46]. Thus the fraction of surface grains
than to generating new small voids. That’s why the voids of the spec­
increases with increasing grain sizes could be attributed as the reason of
imen with large average grain size have less fraction and larger size.

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W. Gao et al. Materials Science & Engineering A 861 (2022) 144361

Fig. 15. Schematic illustrating the deformation and fracture mechanism of FG and CG specimens.

The plastic deformation and fracture mechanisms of specimens with becomes more difficult, which lead to the activation of multiple
fine-grains and coarse-grains are illustrated in Fig. 15. For the specimen slip systems and stress concentration.
contains fine-grains, since the FG specimen contains more grains and (3) GND density relates to grain size, the specimen with larger
grain boundaries, plastic deformation can proceed more uniformly in average grain size has less GND density. Grain orientation also
the grains. Dislocations moving to grain boundaries will be hindered by plays a role in controlling GND density distribution. In soft grain,
the grain boundaries to form dislocation plugging and cause concen­ GNDs tend to accumulated near grain boundaries; in hard grain,
tration of stress, voids are formed inside grains and at grain boundaries GNDs tend to stay inside grain; for grain with“medium-orienta­
during the deformation process, and the voids are connected to each tion”, GNDs distribution depends on the sub area with orientation
other to form small cracks as the plastic deformation progresses. In the rotation.
end, the long cracks caused by the cracking of carbides and other in­ (4) Voids play an important role in the fracture. Crack of inclusions
clusions connect each other and the cracks formed by the voids in the causes large voids. For specimens contain fine-grains, large
grains, resulting in the final failure of the sample. For the specimen number of small voids initiate at grain boundaries and inside
contains coarse-grains, since the fraction of grains and boundaries is grains, the connection of the small voids and large voids leads to
less, it is more difficult for coordinated deformation. The plastic defor­ fracture. For specimens contain coarse-grains, small number of
mation depends on individual grains and the surface roughening and large voids initiate at the regions with stress concentration
inhomogeneous of deformation is more obvious. The dimples and micro- induced by heterogenous deformation. The intergranular fracture
voids in the regions with stress concentration tends to coalesce to form and the transgranular fracture jointly control the fracture
bigger voids, the connection of these big voids and the voids caused by behavior of the alloy.
inclusions cracked results in the eventually fracture.
CRediT authorship contribution statement
5. Conclusion
Wenjie Gao: Methodology, Investigation, Software, Writing original
In this study, the flow stress, strain localization, plastic deformation manuscript. Junxia Lu: Writing – review & editing, Conceptualization.
and fracture mechanisms of Inconel718 specimens with various average Jianli Zhou: Methodology, Software. Ling’en Liu: Methodology, Soft­
grain sizes have been investigated. And the main conclusions could be ware. Jin Wang: Writing – review & editing. Yuefei Zhang: Project
drawn as follows. administration, Supervision, Resources, In-situ equipment. Ze Zhang:
Supervision, Resources, In-situ equipment.
(1) The grain size has significant influence on the mechanical prop­
erties. The YS, UTS and reduction of cross section decrease with
increasing average grain size. The plastic deformation of CG Declaration of competing interest
specimens is more uneven than FG specimens, which is consistent
with the more uneven surface morphology of CG specimens. The The authors declare that they have no known competing financial
necking behavior of FG specimens is more obvious than FG interests or personal relationships that could have appeared to influence
specimens. the work reported in this paper.
(2) The polycrystal Inconel718 specimen deformed coordinately
through activation of slip system and grain rotation. The rotation Data availability
paths of individual grains are different, some follow the classical
modes while the others deviated from <− 112> stable position. Data will be made available on request.
Misorientation tends to accumulated near twin boundaries and
trigeminal grain boundaries. The specimen with large average Acknowledgments
grain size contains less grains and the coordinated deformation
This research was funded by National Science and Technology Major
Project of China(J2019-III-0008-0051) and Key Project of Beijing

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