Effect of surface high-density twinned structure on the fatigue crack initiation of Ti–6Al–4V

Fatigue crack initiation sites would transfer from surface to subsurface of metal specimens through shot peening (SP) or laser shock surface strengthening. This phenomenon is typically attributed to the introduction of compressive residual stress on the surface of the specimen during the surface strengthening process. In this study, Ti–6Al–4V specimens featuring a high-density twinned structure on their surfaces, which eliminated compressive residual stress, were fabricated. Fatigue test result revealed that fatigue crack initiation sites in specimens with twinned structures were predominantly located in the subsurface, near the junction area between the twinned structure and the matrix. This phenomenon was accompanied by an increase in fatigue life. The microstructural features in the fatigue crack source were analyzed using focused ion beam (FIB) coupled with electron backscattered diffraction (EBSD) and transmission electron microscopy (TEM). It was observed that primary crack formed in badly oriented grains that are difficult to initiate dislocation slip according to the Schmid factor (SF). Nonetheless, TEM observations revealed the activation of basal <a> dislocations in these grains, potentially leading to crack nucleation along basal slip bands and subsequent propagation along the basal plane. Our results suggest that a high-density twin structure on the surface can enhance the fatigue strength of Ti–6Al–4V by transferring the fatigue crack source to the subsurface.