Enhancement of fatigue properties of selective laser melting fabricated TC4 alloy by multiple shot peening treatments

Abstract

This study investigated the impact of multiple shot peening (SP) treatments on the surface morphology, microstructure, residual stress and fatigue performance of TC4 alloy manufactured by selective laser melting (SLM). The multiple SP treatments were conducted sequentially using cast steel beads, ceramic beads and glass beads at different peening intensities. In comparison to the conventional single SP process, multiple SP treatments reduced surface roughness and stress concentration coefficient while further increasing the residual compressive stress on the alloy surface. SP significantly enhanced the fatigue life of the alloy by 6.4 to 9.6 times, with a more pronounced improvement observed with multiple SP. Fatigue fracture analysis revealed that the untreated alloy showed multiple fatigue sources which all located on the surface, with surface printing defects acting as potential sites for crack initiation. After SP treatments, all fatigue cracks were initiated beneath the surface. The improved fatigue performance of SLM-formed TC4 alloy could be mainly attributed to the SP-induced surface microstructure refinement and residual compressive stresses. Furthermore, results indicated that, for subsurface crack initiation, the initial cracks primarily stemmed from the fracture of α/α' martensite in the primary β columnar grains.