Advances in Research on Thermal Stability of Surface Nanocrystals in Fatigue-resistant Manufacturing of GH4169 Superalloys

GUO Yifeng; SHEN Zhibin; SONG Runhua; ZHOU Qingwen

doi:10.16490/j.cnki.issn.1001-3660.2026.15.012

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Surface Technology ›› 2026, Vol. 55 ›› Issue (15) : 150-168. DOI: 10.16490/j.cnki.issn.1001-3660.2026.15.012

Surface and Interface Strengthening Technology

Advances in Research on Thermal Stability of Surface Nanocrystals in Fatigue-resistant Manufacturing of GH4169 Superalloys

GUO Yifeng¹, SHEN Zhibin¹, SONG Runhua², ZHOU Qingwen^1,*

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Abstract

Nickel-based superalloys are widely used in aerospace and gas turbine applications due to their excellent mechanical properties. However, during long-term service under high temperatures, high pressures, and complex loading conditions, these components are prone to thermal fatigue failure. Surface nanocrystallization can effectively refine the surface grain structure and enhance fatigue performance, but nanocrystalline grains are susceptible to coarsening at elevated temperatures, which significantly diminishes the beneficial effect. Focusing on the thermal stability of surface nanocrystals in GH4169 superalloy for fatigue-resistant manufacturing, the work aims to systematically review the research progress from the following three aspects.
Firstly, regarding the fatigue performance of high-temperature alloys, this work provides a multi-scale analysis spanning from macro- to micro-level perspectives. At the macroscopic scale, it examines the effect mechanisms of loading conditions (e.g., stress amplitude, mean stress, loading frequency), environmental factors (e.g., temperature, oxidation, corrosive media), and processing routes on the fatigue failure behavior of high-temperature components. This analysis allows for the identification of common fatigue failure modes and general behavioral patterns in these materials. Building on this foundation, the discussion proceeds to the microscopic level, where it investigates how microstructural features such as the type, distribution, and size of precipitates, as well as grain dimensions affect the mechanisms of fatigue crack initiation and propagation. This section underscores the pivotal role of precise microstructural control in optimizing fatigue performance.
Secondly, the review summarizes research advances in various surface nanocrystallization techniques, specifically shot peening, laser shock peening, and ultrasonic surface rolling, aimed at enhancing the fatigue performance of materials through surface modification and microstructural optimization. To tackle the challenge of microstructural degradation under high-temperature service conditions, it further investigates the recrystallization evolution behavior of nanostructures at elevated temperatures and elucidates the underlying mechanisms governing their thermal stability.
Thirdly, the evolution of thermal stability in nanostructures as a function of grain size is systematically elucidated, identifying anomalous thermal stability phenomena and defining the critical size range within which they exist. Subsequently, it provides a systematic analysis of the evolution of plastic deformation mechanisms across different grain size regimes, clarifying the transition of the dominant deformation mechanism from intragranular dislocation slip to grain boundary-mediated processes when the grain size decreases below a critical threshold. Specifically, at larger grain sizes, plasticity is primarily governed by the multiplication, glide, and interaction of dislocations. However, as the grain size refines, the significant increase in grain boundary volume fraction severely restricts intragranular dislocation activities. Consequently, interface-dominated mechanisms such as grain boundary sliding, grain boundary diffusion, and grain boundary migration emerge as the key pathways for coordinating plastic deformation. Finally, using the representative high-temperature alloy GH4169 as a case study, and incorporating micro-scale investigation techniques such as molecular dynamics simulations and in-situ transmission electron microscopy, this review focuses on revealing how specific plastic deformation mechanisms induce grain boundary structural relaxation and reconstruction, thereby determining the intrinsic relationship and regulatory mechanisms governing material thermal stability.
Based on the above contents, this work strives to establish the intrinsic relationship among plastic deformation mechanism, nanostructure characteristics, and thermal stability, aiming to provide theoretical support for obtaining high-temperature alloys with both persistent fine-grain strengthening and high thermal stability through process design. Finally, the current deficiencies in research and future directions are analyzed.

Key words

high-temperature alloy / fatigue performance / surface nanocrystallization / thermal stability

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GUO Yifeng, SHEN Zhibin, SONG Runhua, ZHOU Qingwen. Advances in Research on Thermal Stability of Surface Nanocrystals in Fatigue-resistant Manufacturing of GH4169 Superalloys[J]. Surface Technology. 2026, 55(15): 150-168

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Funding

National Natural Science Foundation of China Youth Fund Project (12402410); Guangdong Basic and Applied Basic Research Foundation Project (2022A1515110059); National University of Defense Technology High-Level Scientific and Technological Innovation Talent Introduction Project (202401-YJRC-XX-023)