Engineering Failure Analysis 131 (2022) 105839

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Engineering Failure Analysis

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

Fatigue fracture of surface-modified layers in 18CrNiMo7-6

carburized steel
Yue Zhang, LiuCheng Lu, GuangTao Xu, Gang Wang *, MingHao Zhao *
School of Mechanical and Power Engineering, Zhengzhou University, Zhengzhou, Henan 450001, China
Henan Key Engineering Laboratory for Anti-fatigue Manufacturing Technology, Zhengzhou University, Zhengzhou, Henan 450001, China

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

Keywords: A modified layer of a certain thickness is produced on the surface of 18CrNiMo7-6 alloy steel after
Surface-modified layers carburizing and quenching that greatly affects the microstructure and fatigue properties of the
Carburized steel material. In this work, the fatigue performance of each layer was studied. The fatigue fracture and
Fatigue
tensile fracture were compared under different depths of the modified layer. The fatigue fractures
Fracture
of the modified layer for different stresses were analyzed. As the depth of the modified layer
increased, the slope of the S–N curve gradually decreased. As the depth of the modified layer
increased, the fracture mode changed from brittle fracture to brittle-ductile mixed fracture, the
shear lip became thicker, and the dimple became larger. There was no flat area in the tensile
fracture. At the same depth of the modified layer, a smaller stress amplitude, led to a larger
proportion of the crack propagation area.

1. Introduction

Fatigue fracture [1,2] is an important failure mode. There is no obvious macroscopic plastic deformation before the failure of parts,
and there is no forewarning of fatigue failure; therefore, it often has very serious consequences, which may lead to economic losses and
casualties. The fatigue fracture is not only affected by the material itself but also by external conditions. Different materials, processing
methods, strengthening methods, and loading conditions result in different fracture morphologies. By analyzing the morphology of the
fatigue fracture, valuable information can be obtained, which provides an important basis for the study of fatigue fracture mechanisms
and the prevention of fatigue fracture.
Kumar et al. [3] compared the fracture surfaces of three different additively manufactured 316L austenitic stainless steels and
observed that the fracture of the BJP (binder jet printing) sample exhibited ductile dimple fracture characteristics, whereas that of the
SLM (selective laser melting) sample did not. The source of cracks in the BJP sample appeared on the surface of the sample, and the
source of cracks in the SLM sample appeared at the machined holes near the surface. Liu et al. [4] also observed that the source of the
crack appeared at the processing hole. Bakhtiari et al. [5] observed that the sample fractures were all ductile, and consisted of pits with
different size distributions for different annealing times. Image analysis of the fracture morphology revealed that a longer annealing
time led to a smaller dimple size. Kim [6] observed that the facet size of the fracture of the precipitation-hardened steel after pre-
straining was reduced, indicating that the dislocation structure formed in the pre-straining process hindered the crack propagation
through the cleavage mechanism. With increasing pre-strain rate, the high-cycle fatigue resistance of the precipitation -hardened steel

* Corresponding authors at: School of Mechanical and Power Engineering, Zhengzhou University, Zhengzhou, Henan 450001, China.
E-mail addresses: wanggang@zzu.edu.cn (G. Wang), memhzhao@zzu.edu.cn, memhzhao@sina.com (M. Zhao).

https://doi.org/10.1016/j.engfailanal.2021.105839
Received 23 March 2021; Received in revised form 18 October 2021; Accepted 29 October 2021
Available online 1 November 2021
1350-6307/© 2021 Elsevier Ltd. All rights reserved.
Y. Zhang et al. Engineering Failure Analysis 131 (2022) 105839

improved slightly. This is because the combined effect of the pre-strain increases the resistance to crack initiation and reduces the
ability to resist crack growth. Li et al. [7] observed that a crescent-shaped damage zone was formed in front of the crack tip under
overloading in DP780 dual-phase steel; the fracture morphology was characterized by cleavage surfaces, tear ridges, dimples, and
cavities. There is no significant interaction between crack branching and crack propagation delay under overload. Yang et al. [8]
examined the fractures of all the failed samples and observed that all the fatigue cracks originated from the surface of the samples; it
can be summarized as single-point surface crack initiation and multi-point surface crack initiation. Xiao et al. [9] observed that all the
fracture samples started from the surface or from the subsurface layer of aluminum-rich calcium-rich non-metallic inclusions, and the
fracture surface showed characteristics of intergranular fracture and dimple formation. Liu and Ma [10,11] also observed fatigue
cracks caused by internal non-metallic inclusions and/or an internal matrix in the fracture surface of the rotating bending fatigue test.
Xu et al. [12] studied the initiation and propagation of micro-cracks in high-strength aluminum alloys during ultra-high-cycle fatigue
and observed two different crack initiation modes: one from the inside of the specimen with fish-eye characteristics and the other from
the surface. Apple et al. [13] observed that the fracture surface of carburized steel showed a mixed intergranular and transgranular
fracture mode. Chauhan et al. [14] observed that the fracture of 9Cr-ODS steel at room temperature consisted of a ductile dent tear,
which differed from the large radial crack parallel to the tensile axis. As the temperature increased, the fracture surface formed at the
outer periphery. There was a shear lip area, and the size of the pit increased. The depression of the crack surface indicates that the intra-
grain crack propagated, leading to damage. At 650 ◦ C, the fracture mechanism changed from intragranular fracture to intergranular
fracture. At 800 ◦ C, the fracture mechanism completely changed to intergranular fracture; therefore, it is concluded that the change of
the damage mechanism results from the change of the deformation mechanism. Chai et al. [15–17] used dislocation theory and basic
research in fracture mechanics to explain the formation of nanopores, the formation of fine-grained regions, and crack initiation in
martensitic steel during very high cyclic fatigue testing. The annihilation of dislocations during the loading process may lead to va­
cancies or eventually the formation of nanopores, and local stress concentration will lead to the formation of fine grain regions and
crack initiation. Yang et al. [18,19] conducted high-temperature tensile-compression fatigue studies on bainitic steel, and observed
that there are almost parallel secondary cracks on the fracture surface. The formation of secondary cracks can reduce stress con­
centration and dull the crack tip. To enhance the crack –propagation resistance, the formation of secondary cracks in the process of
fatigue crack propagation may be related to the parallel arrangement of the ferrite/austenite interface. Previous research work has
focused more on the evaluation of the overall fatigue performance of the material, either the study of homogeneous materials or the
overall study of gradient materials. For strengthened materials, the strengthened layer often belongs to a gradient structure. The
evaluation of the fatigue performance of the gradient structure layer and the study of the fracture mode will help to better reveal the
fatigue resistance mechanism of the strengthened material.
18CrNiMo7-6 high-strength steel [20–22] has good mechanical and processing properties and is therefore widely used in many
industrial components, especially in the field of high-speed heavy-duty gears. Pöhl studied the residual austenite deformation and
phase transformation behavior of 18CrNiMo7-6 steel after high-carbon surface hardening treatment during nanoindentation. Zhou
et al. [23] studied the nano-mechanical properties of the indentation size effect and the yield strength of the surface-hardened
18CrNiMo7-6 steel surface modification layer through nanoindentation experiments. The experimental results indicate that the
hardness increases with increasing strain rate. As the residual compressive stress relaxes, the curve of contact strength and indentation
depth is convex. Xu et al. [24] used the tensile test method to determine the elastoplasticity of the surface modification layer of
18CrNiMo7-6 carburized alloy steel and gave the relationship between the hardness of the tensile specimen and the carbon content
from the tensile test and stress–strain curve. The curve is used to determine the elastic modulus, yield strength, and hardening index of
the surface modified layer. Previously, the 18 CrNiMo7-6 carburized steel was treated in layers to study the relationship between the
residual stress and the microstructure and corrosion resistance at different carburized layer depths. The results are presented in the
literature [25]. The fatigue behavior of 18CrNiMo7-6 carburized steel under different carburizing depths was studied, and the main
purpose was to further understand the relationship between the carburizing depth of carburized steel and the fatigue properties. In
addition, some other factors affecting the fatigue properties of carburized steel and the relationship between the fatigue fracture
characteristics and tensile fracture characteristics of carburized steel are discussed.

2. Materials and methods

2.1. Materials and preparation

The material used in this research was a carburized gear steel 18CrNiMo7-6. The composition is shown in Table 1. The material was
maintained at 920 ◦ C with 1.2%, 1.1%, and 0.9% carbon potential for 17, 7, and 10 h, respectively; after that, it was tempered at 650 ◦ C
for 2 h. It was reheated to 820 ◦ C for 2 h and quenched in oil, deep cooled at − 60 ◦ C for 2 h, and finally tempered at 180 ◦ C for 10 h. A
schematic diagram of the cutting of the fatigue specimen along the depth of the surface-modified layers is presented in Fig. 1. The
fatigue sample size was designed using the “GBT3075-2008 Axial Force Control Method for Fatigue Test of Metallic Materials”[26].

Table 1
Chemical composition (mass %) of the 18CrNiMo7-6 steel.
Cr Ni Mo Mn C Si P S Fe

1.50–1.80 1.40–1.70 0.25–0.35 0.50–0.90 0.15–0.21 0.40 ≦0.035 ≦0.035 Balance

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Y. Zhang et al. Engineering Failure Analysis 131 (2022) 105839

The dog-bone-shaped specimens for the fatigue tests had a gauge section of 15 mm × 5 mm × 0.5 mm and a total length of 50 mm. A
total of seven layers of samples were cut from the surface to the core. The depth of each layer to the surface is shown in Table 2.

2.2. Methods

An American MTS 370.0215kN double-column floor-type axial fatigue test system was used for the fatigue test. The axial tensile
stress control mode was adopted in the fatigue test. A sinusoidal waveform signal with a frequency of 5 Hz was adopted, and the stress
ratio was R = 0. All the fatigue tests were performed until the specimen was broken or the number of cycles reached 1,000,000. The
specimens were divided into seven groups. At least 4 stress levels were selected for each fatigue test, and 3–5 specimens were selected
for each stress level. The range of the stress level was 0.65–1 σs , where σ s is the yield strength. The yield strength [24] of 1–7 layers of
surface modified layer after delamination was 1694, 1667, 1526, 1281, 980, 894, and 875 MPa, respectively. During the test, loading
was started from the high stress level, and the stress levels were measured to construct an S–N curve of the fatigue life. The sample was
relatively thin, and some data may deviate greatly from the actual data in the test results; therefore, it is necessary to make appropriate
choices to ensure the accuracy of the test results. The fracture of the sample was analyzed using a ZEISS focused ion beam/scanning
electron microscope, with a working voltage of 15 kV using the SESI probe. All the experiments were performed at room temperature.

3. Results

3.1. S–N curve

Fig. 2 presents the S–N curve at different depths of surface-modified layers. The points represent the test values. The relationship
curve between the cyclic stress and fatigue life was determined using the Busquin formula. The relationship between the stress
amplitude and fatigue life is expressed in the form of a power function, and the fitting results give the following equations:
( )0.0857
σa × Nf = 3022.29(Depth : 2.175mm) (1)

( )0.0752
σa × Nf = 2508 ⋅ 96(Depth : 3 ⋅ 125mm) (2)

( )0.0198
σa × Nf = 1169 ⋅ 18(Depth : 4 ⋅ 075mm) (3)

( )0.0110
σa × Nf = 100 ⋅ 31(Depth : 5 ⋅ 025mm) (4)

( )0.0395
σa × Nf = 1345 ⋅ 67(Depth : 5 ⋅ 975mm) (5)

It can be observed from the S–N curves at different depths in Fig. 2 that as the depth increased, the slope of the S–N curve gradually
decreased, and the S–N curve gradually moved down, indicating that at the same maximum cyclic stress, the fatigue performance of the
material gradually deteriorated with increasing depth. It can also be observed from Fig. 2 that at the same depth, a higher stress level
resulted in a shorter life. The S–N curve was not obtained for the first two layers because of the properties and test conditions of the
material itself. The materials of the first two layers were too brittle, and the sample was thin. If the clamping force is small, the sample
will slide, and if the clamping force is large, stress concentration will occur, resulting in breakage from the specimen holding end. Both
situations will cause the data to be unusable. Table 2 lists the parameters of the fatigue test on the surface-modified layer and the
fatigue life obtained at different stress levels.

Fig. 1. Schematic diagram of cutting of the fatigue specimen along the depth of surface-modified layers.

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Y. Zhang et al. Engineering Failure Analysis 131 (2022) 105839

Table 2
Fatigue test parameters and fatigue life at different depths
Depth/mm Stress amplitude Loading frequency/Hz Stress level/MPa Life

1 σs = 1694 3557
0.375 0 5 0.9 σs = 1524.6 2388
1.225 0.9 σs = 1500.3 3245
0.8 σs = 1333.6 13975, 9725
0.7 σs = 1166.9 4768, 5748
2.175 1 σs = 1526 9107, 10910
0.95 σs = 1449.7 9450,
0.925 σs = 1411.6 22270, 19043
0.9 σs = 1373.4 26,406
0.85 σs = 1297.1 15,159
0.8 σs = 1220.8 26,990
0.75 σs = 1144.5 16,527
0.7 σs = 1068.2 86,646
3.125 1 σs = 1281 8827
0.95 σs = 1216.95 24829, 26014
0.9 σs = 1152.9 38597, 16914, 20161
0.85 σs = 1088.85 65657, 6353293018, 59555850,5841,217,461
0.8 σs = 1024.8
0.75 σs = 960.75
0.7 σs = 896.7
4.075 1 σs = 9800.95 σs = 9310.925 σs = 906.5
0.91 σs = 891.8 74296, 104742
61044, 105791, 211635
125006, 88538, 98520, 199845, 113907, 166356
1,323,259
5.025 1 σs = 894 75552, 77686
0.975 σs = 871.65 426964, 946710
0.95 σs = 849.3 98174, 496702, 1000000
5.975 1.1 σs = 962.5 58984, 92942, 69298
1 σs = 875 71619, 59111, 89284
0.95 σs = 831.25 104620, 132633
0.9 σs = 787.5 938,520

Fig. 2. S-N curves at different depths of the surface-modified layers.

3.2. Fatigue fracture

The fracture of most fatigue specimens consists of three parts: the crack initiation zone, the crack propagation zone, and the
instantaneous fracture zone. Three areas are marked in Fig. 4 (g).The load and fatigue life under different modified depths are shown in
Table 3.

3.2.1. Macroscopic analysis of fatigue fracture

Fig. 3 presents an overall macroscopic view of the sample fracture. It can be observed that the first three layers of fractures are

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Y. Zhang et al. Engineering Failure Analysis 131 (2022) 105839

Table 3
Load and fatigue life under different modified depths
Depth/mm Load/MPa Life

0.375 0.9 σs = 1524.6 2388

1.225 0.9 σs = 1500.3 3245
2.175 0.9 σs = 1373.4 26,406
3.125 0.9 σs = 1152.9 38,597
4.075 1.0 σs = 980 104,742
5.025 0.95 σs = 849.3 98,174
5.975 0.95 σs = 831.25 104,620

Fig. 3. Overall macroscopic view of the sample fracture.

straight fractures perpendicular to the direction of the loading force, and there is no obvious plastic deformation near the fractures. The
fracture of the last four layers consists of a straight fracture perpendicular to the direction of the loading force and an oblique straight
fracture with an angle of 45◦ to the direction of the loading force, and obvious plastic deformation occurs near the oblique and straight
fracture. It can be preliminarily drawn from Fig. 3 that the first three layers are brittle fractures and that the last four layers are ductile

Fig. 4. Macroscopic fractures under different modified depths, (a)0.375 mm, (b)1.225 mm, (c)2.175 mm, (d)3.125 mm, (e)4.075 mm, (f)5.025 mm,
(g)5.975 mm.

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Y. Zhang et al. Engineering Failure Analysis 131 (2022) 105839

and brittle mixed fractures. For further confirmation, overall views of the fatigue fractures at different modified depths are presented in
Fig. 4. Fig. 4 (a)–(g) correspond to Fig. 3 (1–1)–(7–1), respectively. It can be observed from Fig. 4 that the first layer of the fatigue
source appears on the surface of the sample, and the remaining six layers all appear at the edge, indicating that the stress concentration
at the edge is relatively large. The fractures of the first three layers were relatively flat, with no fiber zone or shear lip. Therefore, the
first three layers were brittle fractures. The last four layers of the fracture had a flat fracture zone and a fracture zone composed of fiber
and shear zones. Therefore, the last four layers were ductile and brittle mixed fractures, and the flat zone became larger with increasing
depth (as shown in the corresponding figure for the flat zone). Finally, straight fracture was observed. As the depth increased, the shear
lip became thicker, and the seventh shear lip was the thickest. Fatigue ratcheting marks appeared at the edges of the fracture surface of
the seven-layer specimens.

3.2.2. Analysis of microscopic appearance of fatigue fracture

Fig. 5 shows the characteristic fracture images of fatigue source areas with different modified depths. The yellow curve is the crack
source, and the arc-shaped river pattern or shell-like pattern diverging from the crack source is the crack propagation area. Fig. 6 shows
the microscopic morphology of the crack propagation zone at different depths of the modified layer. It can be observed from Fig. 6 that
many secondary small cracks (indicated by the arrow) appeared in the crack propagation area of the seven-layer sample, and small
intergranular cracks (indicated by the white arrow) appeared in the first two layers. The occurrence of fatigue lines is related to the
strength of the material, and it is not easy to observe fatigue lines on materials with higher strength. It can also be observed from Fig. 6
(a) and (b) that there were a large number of massive cleavage surfaces, and Fig. 6(c) and (g) show river-like cleavage surfaces. The
fracture in the instantaneous area was rougher than that in the crack source and propagation area. The fracture in the transient zone
can be ductile fracture or brittle fracture and is related to the strength and shape of the material itself as well as the size and loading
method of the material. Fig. 7 presents SEM images of the microscopic morphology of the center of the transient zone at different
depths of the modified layers. As the depth of the metamorphic layer increased, the dimples became larger and deeper. The average
size of dimples from the surface layer to the substrate was 0.58, 0.63, 1.05, 1.2, 1.31, 1.39, and 1.41 μm.

Fig. 5. Fatigue sources at different modified depths, (a)0.375 mm, (b)1.225 mm, (c)2.175 mm, (d)3.125 mm, (e)4.075 mm, (f)5.025 mm,(g)
5.975 mm.