Effect of grain boundary phase formed by Mn addition on initiation and propagation of fatigue cracks in homogenized Cu-6Ni-1.3Si alloy

Abstract

High-strength cast Cu alloys often contain substantial quantities of alloying elements that promote the nucleation of heterogeneous particles, particularly at grain boundaries (GBs). In the Cu-6Ni-1.3Si alloy, intermetallic compounds such as Ni2Si form within the matrix and along the GBs following homogenization. Ni2Si particles within the matrix are homogeneously nucleated with diameters of a few tens of nanometers, which enhances matrix strength. However, heterogeneously nucleated Ni2Si particles at GBs, which can be several micrometers in size, negatively impact overall strength. To improve the strength of Cu-6Ni-1.3Si alloy, 2.1 wt% Mn was added. This Mn addition led to the formation of plate- or film-shaped intermetallic compounds, specifically Ni16Si7Mn6 (G-phase), at GBs after homogenization. Despite the Mn addition, Ni2Si precipitates with diameters of a few tens of nanometers still formed within the grains, but these were more densely distributed in the Mn-added alloy compared to the Mn-free alloy. Fatigue tests conducted on round bar specimens of both alloys showed that Mn addition enhanced fatigue strength. This enhancement is attributed to the suppression of both crack initiation and propagation along the GBs and within the matrix. © 2024 Elsevier Ltd