etude experimentale de la propagation de fissures de fatigue dans la zone affectee thermiquement de joints soudes de roues de turbines hydrauliques

This thesis presents the results of a comprehensive experimental study on the fatigue crack propagation behavior in aqueous environment of the heat affected zone of CA6NM stainless steel hydraulic turbine runner welds. The initial objective of this project was to determine the fatigue crack growth properties of the heat affected zone. To achieve this, standardized fatigue crack growth tests in aqueous environment were performed to determine the crack growth threshold DeltaKth, and the Paris relationship constants C and m of the heat affected zone. Given potential experimental uncertainties arising from the growth of a crack confined to the heat affected zone, fatigue crack growth tests in an aqueous environment at constant stress intensity factor range (DeltaK) were performed so that the crack would propagate across the heat affected zone. These tests allowed to better appreciate the fatigue crack growth resistance variation between the three zones of the weld, i.e., the filler metal, the heat affected zone and the base metal.;Various experimental objectives were supplemented to these two primary objectives. A CA6NM plate was welded to generate a layer of filler metal over its entire surface. The welded plate was cut in two equal pieces, one of which was post-weld heat treated in order to study the effect of this treatment on the fatigue crack growth behavior. Compact tension type fatigue specimens were machined from the welded plates. Rectangular samples were also collected to allow the characterization of the weld. Metallographic observations and X-ray diffraction measurements of the three zones of the weld (filler metal, heat affected zone and base metal) were conducted in order to characterize the microstructure. This microstructural characterization combined with metallographic observations of the crack path profiles were useful in assessing the microstructural effects acting on the fatigue crack growth behavior of the weld. Microhardness measurements were carried out across the weld in order to quantify the heat affected zone width and to allow a relative mechanical characterization of the three weld zones. Residual stresses were measured in fatigue specimens to determine their influence on the fatigue crack growth behavior. Finally, the fracture surfaces were observed using a scanning electron microscope in order to identify the main fracture mechanisms.;This work led to several conclusions about the fatigue crack growth behavior in aqueous environment of hydraulic turbine runner welds, and especially in the heat affected zone. First, the measured crack tip tensile residual stresses inhibited crack closure, which resulted in a deteriorated resistance to fatigue crack growth. On the other hand, the beneficial effect of post-weld heat treatment was explained by its ability to sufficiently reduce the tensile residual stresses to allow crack closure to occur. Secondly, the martensitic microstructure of the three weld zones was identified as influencing the fatigue crack growth behavior. The varying martensite coarseness between the three weld zones influenced the path of the crack. A fine martensitic microstructure, as observed in the weld metal, resulted in a linear crack path, while a coarse microstructure, as observed in the heat affected zone and base metal, resulted in a tortuous crack path. The degree of crack path tortuosity was related to the fatigue crack growth resistance, which revealed that a coarse martensitic microstructure that leads to a tortuous crack path, promotes toughening by local mixed modes of crack advance and roughness-induced crack closure. Thirdly, when the crack propagated in the heat affected zone, a tendency to gradually deviate towards the base metal was observed. This behavior was rationalized by considering the yield strength mismatch between the three weld zones. The yield strength decreased in the heat affected zone from filler metal to base metal. Finally, the presence of residual and/or reformed austenite in the three zones of the weld, as well as the occurrence of an intergranular fracture mechanism in the heat affected zone and base metal were identified as having a negligible influence on the fatigue crack growth behavior in the amounts measured.;The main conclusion of this study is that the heat affected zone is only slightly less resistant to fatigue crack growth than the base metal. This was attributed to its somewhat finer microstructure that leads to a less tortuous crack path. It is rather the weld-induced residual stresses that dominantly affect the growth of fatigue cracks in hydraulic turbine runner welds. From a practical point of view, the results of this research allow to assert that the turbine runner welding process combined with a post-weld heat treatment produce a weld with good resistance to fatigue crack growth. (Abstract shortened by UMI.).