Fatigue Crack Growth Rate Description of RF-Plasma-Sprayed Refractory Metals and Alloys

A fitting method capable of describing the fatigue crack growth rate (FCGR) data in all stages of crack propagation by a simple Forman-style analytical formula was developed. To demonstrate its robustness, this method was used to quantify the fracture behavior of RF-plasma-sprayed W, Mo, W-Mo composite, and four selected Ni-based tungsten heavy alloys (WHA). The fitted FCGR parameters categorized the studied materials into two distinct sets. W, Mo, and W-Mo composite deposits made from inherently brittle refractory metals that contained a range of defects inherent to plasma spray process represented the first class. This class was characterized by low fracture toughness and a relatively wide range of fatigue crack growth thresholds. The second class of materials was represented by WHA. Here, the deposit defects were suppressed by liquid state diffusion that formed a typical WHA structure consisting of a Ni-rich matrix and large spherical W reinforcement particles. The WHA generally showed higher fatigue crack growth thresholds, but differed in fracture toughness values based on the W particle concentrations. The obtained fracture mechanical data represent a reference dataset of plasma-sprayed refractory materials, and their classification into groups clearly demonstrates the capabilities of the developed method to capture a wide range of different types of FCGR behavior.