Research on the fatigue failure behavior of 1Cr17Ni2 blades ground by abrasive belt with passivation treatment

•Passivation treatment of abrasive belt can effectively improve surface integrity of aero-engine blades.•The passivated abrasive belt grinding can promote the grain refinement and microstructure homogenization of the machined surface.•Blade of passivated abrasive belt grinding can suppress the initiation of fatigue cracks on the surface and prolong fatigue life of aero-engine blades.•An anti-fatigue grinding method with blunt grinding and slow feed was proposed. As precision machining process of aero-engine blades, the surface integrity after abrasive belt grinding closely related to its fatigue resistance. In order to explore new anti-fatigue abrasive belt grinding methods, reveal the influence mechanism of blade surface integrity on anti-fatigue performance, and provide guidance for the anti-fatigue grinding, vibration fatigue tests were carried out on blades processed by different grinding process, and the effects of abrasive belt passivation treatment and feed speed on blade surface integrity and fatigue life were studied. Fatigue failure behavior of blades processed by different processes were also discussed from the fracture morphology and cross-section analysis. Results showed that blades processed by blunt grinding have different fatigue failure mechanisms, and the passivation treatment of abrasive belt and low feed speed can improve the surface integrity and fatigue life of aero-engine blades. The combination process of abrasive belt passivation treatment and slow feed speed were proposed for anti-fatigue grinding processing of aero-engine blades. In this research, compared with blades processed by new abrasive belt with feed speed 1000 mm/min, the fatigue life of blades processed by passivated abrasive belt at feed speed 100 mm/min was increased by 3.1 times.