Effect of rolling on crack behavior of FeCrAl alloys in ultra-long life

Purpose The purpose of this paper is to determine (1) the relationship between microstructure and fatigue cracking behavior and (2) effect of rolling on the process of crack initiation and propagation in FeCrAl alloys. Design/methodology/approach The qualitative and quantitative fracture studies were performed using scanning electron microscopy and the non-contact optical measurement system (IFMG5). Findings The results show that the formation of facets, rough facets and parallel stripes in the crack initiation and early crack propagation zones are closely related to the sensitivity of crack behavior to the microstructure of the material. Besides, the rolling process has a significant influence on the small crack initiation and propagation behavior. Quantitative analysis demonstrates that the size of the stress intensity factor and plastic zone size in the rough zone is associated with the rolling process. Originality/value The findings of this study have the potential to enhance the understanding of the microstructural crack formation mechanisms in FeCrAl alloys and shed light on the impact of rolling on the long-term and ultra-long fatigue behavior of these alloys. This new knowledge is vital for improving manufacturing processes and ensuring the safety and reliability of FeCrAl alloys used in nuclear industry applications.