Maximum Compressive Residual Stress Research Articles

Comparison of the effects of induction heating composite shot peening and conventional shot peening on residual stress, microhardness, and microstructure of 20CrMnTi gear steel

As a commonly used surface strengthening technology, shot peening, which can significantly improve the fatigue strength of mechanical parts, is widely used in the fields of vehicles and aviation. To obtain a larger residual compressive stress and further refine the grain size under normal shot peening intensity and coverage, this study proposes an induction heating composite shot peening (IHCSP) surface strengthening method, aiming to utilize the coupling effect of temperature and stress fields to promote the shot peening strengthening effect. An IHCSP test plan was designed and an IHCSP test bench was created to achieve simultaneous induction heating and shot peening. This study compares the surface integrity parameters and microstructures under three processes: un-peened, conventional shot peening, and IHCSP. The results show that the maximum axial and radial compressive residual stresses increase by 72.41 and 75.4 MPa respectively; the depth of the hardened layer increases by 0.3 mm, the martensitic transformation more complete, the grain size decreases by 483 nm, the dislocation density increases significantly, and nanocrystals are obtained on the surface of the material. These results verify the superiority of IHCSP surface strengthening.

A comprehensive study on the effects of surface post-processing on fatigue performance of additively manufactured AlSi10Mg: An augmented machine learning perspective on experimental observations

In this study, the efficacy of 21 distinct surface post-processing methods on the fatigue behavior of an additively manufactured (AM) material was investigated. Various treatments, encompassing single-step processes like sand blasting (SB), conventional shot peening (CSP), severe shot peening (SSP), gradient severe shot peening (GSSP), ultrasonic shot peening (USP), severe vibratory peening (SVP), ultrasonic nanocrystal surface modification (UNSM), laser shock peening (LSP), laser polishing (LP), tumble finishing (TF), chemical polishing (CP), electro-chemical polishing (ECP), and machining (M), as well as hybrid treatments, were systematically investigated for their impact on the fatigue behavior of hourglass laser powder based fused (LB-PBF) AlSi10Mg specimens. A comprehensive series of experimental tests were carried out, covering surface texture analyses, microstructural characterizations, porosity measurements, hardness, residual stresses (RS), monotonic tensile tests, and rotating bending fatigue tests at four stress levels. Following the experimental investigations, the acquired data were leveraged to develop a machine learning (ML)-based model to correlate the fatigue life with the influencing factors and conduct parametric and sensitivity analyses. The model utilized a deep learning approach to predict the fatigue response of LB-PBF AlSi10Mg, incorporating various artificial neural networks (ANNs) and considering input parameters such as yield strength, ultimate tensile strength, elongation to fracture, porosity, depth of pore closure, surface hardness, depth of hardness variation, surface RS, maximum compressive residual stresses (CRS), depth of the CRS field, top surface grain size, surface layer mean grain size, surface roughness, and stress amplitude. Depending on the life regime, the factors influencing fatigue behavior can vary significantly. In higher stresses, dominated by plastic strains, surface residual stress emerges as the primary factor. Conversely, in lower stresses, dominated by elastic strains, the significance of surface roughness becomes more pronounced, followed by surface residual stress, surface hardness and other factors. These findings underscore the contextual importance of different influencing factors for enhancing fatigue resistance based on varying loading conditions.

Effect of multifunction cavitation on microstructure and plane bending fatigue properties of low-alloy steel

Multifunction cavitation (MFC) has potential as an environmentally friendly surface-modification method. In the present study, the modified surface layer and the fatigue properties for MFC-processed low-alloy steel were investigated. When the processing time was longer than 2 min, the surface roughness increased and the surface potential decreased. The maximum compressive residual stress was induced after a processing time of 2 min, and decreased for longer processing times. Electron backscatter diffraction analysis of a cross section of a sample subjected to MFC for 30 min showed that the modified layer was thicker than that for samples processed for shorter times. The fatigue life at high cycle numbers increased for the specimens processed by MFC under the conditions corresponding to the greatest compressive residual stress. MFC processing was shown to be effective in improving the fatigue properties of steel, and therefore has potential as a next-generation surface-modification method.

Evidence of microstructural evolution linked to non-monotonic distribution of micromechanical properties induced by shot peening

The residual stress field induced by surface strengthening processes such as mechanical shot peening and other forms of plastic deformation does not generally exhibit a simple “monotonic” distribution trend. Some researchers have analyzed this fact from a mechanical perspective based on Hertz theory. However, the micro/nano-scale microstructural changes corresponding to the distribution of residual stress fields still appear to be lacking. In this study, we focused on a widely used material in aviation manufacturing, namely nickel-based superalloy GH4169, as our experimental material. We subjected GH4169 alloy to mechanical strengthening treatment using a shot peening intensity of 0.25 mmA, followed by quantitative testing of micromechanical performance indicators such as microhardness and residual stress. To thoroughly investigate the relationship between micromechanical properties and microstructure changes, we utilized transmission electron microscopy (TEM) to observe and analyze shot-peened materials at different depths. Our findings revealed that the most severe microstructural distortion induced by mechanical shot peening in GH4169 alloy was likely to occur within a depth range of 25 to 75 μm. This observation aligns with the actual phenomenon that the maximum microhardness and maximum residual compressive stress did not manifest on the outermost surface of the material. By presenting a detailed analysis of deformation defects such as dislocations, stacking faults, and twinning in different depths of mechanically strengthened layers, our study contributes to a deeper understanding and practical application of post-processing technologies based on plastic deformation.

Composite effects of residual stress and hardness gradient on contact fatigue performance of rough tooth surfaces and optimization design of detailed characteristic parameters

Residual stress and hardness gradient significantly affect the contact fatigue failure process of rough tooth surfaces, and the meticulous design of their characteristic parameters can help improve the fatigue resistance of gears. In this paper, an efficient computational method for rough tooth surface contact is established based on the reconstruction modeling of asperities and mixed lubrication analysis. By comprehensively considering the effects of residual stress and hardness gradient, the Dangvan multiaxial fatigue criterion is adopted to predict and analyze the contact fatigue life of the gear surface. The correlation between the surface residual stress, maximum residual stress depth, surface hardness, and effective hardening layer depth, among other characteristic parameters, and the contact fatigue performance of tooth surfaces is established. The results show that: (1) Increasing the magnitude of surface residual compressive stress and surface hardness can significantly reduce the risk of fatigue failure in the near-surface layer of the gear. To achieve the same fatigue performance, there is a linear negative correlation between the design values of the two parameters. (2) Affected by the double stress peaks in the rough tooth surface stress field, the maximum residual stress depth significantly affects the depth at which the highest failure risk occurs. With changes in roughness, the optimal design value of the maximum residual compressive stress depth changes from about 0.5 times the Hertzian contact half-width depth in the subsurface layer (Sa < 0.2 μm) to about 15 μm in the near-surface layer (Sa > 0.4 μm). (3) Considering both process cost and gear surface fatigue resistance, the design threshold for the effective hardening layer depth should be greater than the Hertzian contact half-width. This paper establishes a composite correlation between the meticulous characteristic parameters of residual stress, hardness gradient, and the contact fatigue performance of tooth surfaces, providing theoretical support for optimal design of tooth surface anti-fatigue performance.

Hybrid modeling prediction of residual stresses in turned Ti6Al4V considering frictional contact

Residual stress plays a pivotal role in assessing the surface quality of machined components, influencing characteristics such as fatigue performance, corrosion resistance, and mechanical strength. Ti6Al4V, a critical material in the nuclear sector, the generation of residual stresses during machining has attracted significant attention. A model for variable friction coefficient model is proposed to accurately characterize the complex plastic deformation behavior of the material. This model takes into account variables such as the relative sliding velocity, contact pressure, and temperature. A subroutine has been developed using the VFRIC interface to enhance precise cutting simulation and modeling. Using the friction model, a new hybrid prediction model for surface residual stresses is developed by integrating finite element analysis and analytical methods. The reliability of both the hybrid and friction models is confirmed through the evaluation of cutting forces, chip morphology, and residual stress. The findings suggest that the novel friction model produces simulation results with higher accuracy compared to traditional Coulomb friction models. The variations in cutting force amount to 5.8% and 13.7%, the error in chip serration is 12.4%, and the deviation in predicting the maximum residual compressive stress is 10.3%. This study contributes to the advancement of friction models and methodologies used in predicting residual stress.

Study on CFRP-Strengthened Welded Steel Plates with Inclined Welds Considering Welding Residual Stress.

Welded steel plates are widely used in various structural applications, and the presence of inclined welds is often encountered in practical scenarios. Carbon fiber reinforced polymer (CFRP) has been proven to be effective for strengthening steel structures. However, the behavior of CFRP-strengthened welded steel plates with inclined welds, particularly considering the influence of welding residual stress, is limited. This paper aims to investigate the tensile behavior of CFRP-strengthened welded Q355 steel plates with inclined welds considering welding residual stress (WRS). First, WRS data were obtained by the X-ray diffraction (XRD) method at different locations. The maximum tensile and compressive residual stresses are 0.39 and 0.14 times the yield strength of the steel, respectively. Then, finite element models were established to investigate the effects of weld angles, weld width, and height on the WRS distribution of welded steel plates. Finally, the tensile performance of CFRP-strengthened welded plates with WRS was studied by numerical simulation. The results showed that the weld angles have little effect on the distribution pattern of residual stress but significantly affect the peak tensile WRS. When the weld angle changes from 0° to 60°, the peak tensile WRS decreases significantly from 0.32 to 0.06 times the yield strength of steel; furthermore, the influence of weld width and height on WRS is relatively limited. Under tension loading, the maximum stress occurs near the weld. The ends of the weld enter the yielding state later than the middle part of the weld due to the distribution of the WRS. As the weld angle increases and the length of the weld increases, the stress in the weld zone decreases, while the stress in the base material zone correspondingly increases. In addition, CFRP strengthening can reduce the magnitude of stress. This study provides preliminary references for understanding the tensile behavior of CFRP-strengthened welded steel plates with inclined welds.

Reliability evaluation for shot-peening conditions affecting durability life of automotive suspension coil springs

Shot peening (SP) is a cold working method used to improve the fatigue life and corrosion resistance of metallic materials subjected to repeated loading. However, optimal SP conditions can only be found through experiments with actual operating parts. In addition, studies on the effective SP conditions and ensuring safety for improving the durability of parts are lacking. In this study, SP of various conditions were applied to automobile suspension coil springs (ASCS). Consequently, the process factors, damage assessment, and microstructure were analyzed to determine the factors that exerted a dominant effect on durability life. The durability life of springs applied with stress SP (SSP) was evaluated to be approximately 3.8–4.8 times higher compared to that of springs applied with other SP conditions. In addition, by analyzing the process factors affecting the durability life, the absence of a direct effect of the arc height and Vickers hardness was observed. Moreover, the effect of surface roughness was observed to be small. However, the durability life in response to the change in maximum compressive residual stress (MCRS) exhibited a tendency to change linearly, and this relationship was expressed in an equation through regression analysis. The fracture surface of spring with a high durability life tended to have a large number of spiral shapes, and that of spring with a low durability life tended to have a large number of flat shapes. Before conducting the durability test, a circumferential metal flow was observed in the work-hardened layer below the spring surface upon shot peening. After conducting the durability test, partial crack initiation and propagation and delamination were observed in these areas. Despite the varying SP conditions, the surface microstructure of each spring was observed to be similar before and after the durability test. In this study, it was confirmed that SSP is the most effective method to improve the durability life of ASCS, and it was possible to understand through damage evaluation and microstructure analysis that MCRS affects the durability life by delaying the initiation of cracks in the spring. The analysis method and results of this study are expected to be useful for improving the reliability of not only ASCS but also SP-applied components in the future.

Effect of process parameters on residual stresses in SLM-formed bionic porous titanium alloy structures

Bionic porous titanium alloy structures have demonstrated broad application prospects in the field of biomedicine, and selective laser melting (SLM) has become one of the main methods for preparing porous titanium alloy structures due to its high degree of forming freedom. Residual stress is a crucial indicator for evaluating the forming quality of SLM parts, thus its control methods have garnered significant attention. Therefore, it is important to understand the process parameters' influence on the generation and regulation of residual stresses in SLM-formed bionic porous titanium alloy parts. In this paper, finite elements and experiments are employed to research the relationship between process parameters and residual stresses in the SLM process, and a method for controlling residual stresses in the key sensitive areas is proposed. It is found that increasing the laser scanning speed is conducive to reducing the residual stress of the porous structure and alleviating the phenomenon of stress concentration. Appropriately increasing the laser power can reduce the residual stress in the Z direction of the porous structure, with the optimal range being from 200 W to 250 W. Using a medium laying powder thickness (0.03 mm∼0.04 mm) results in uniformly distributed residual stress on the surface of the porous structure, leading to the attainment of maximum residual compressive stress. Building upon this foundation, the experimental verification of forming quality established stability, while the derived parameter optimization method and forming mechanism offered theoretical support for process optimization in fabricating porous titanium alloy structures through SLM.

Effect of surface strengthening by ultrasonic shot peening on TC17 alloy

This paper investigates the effects of ultrasonic shot peening (USP) on surface morphology, microstructure, and residual stress field distribution of TC17 alloy under different process parameters. The aim is to reveal the surface strengthening mechanism of TC17 alloy caused by USP. The results suggest that the use of the 2.5 mm projectile diameter leads to an increase in surface roughness, plastic deformation, and a deeper grain refinement layer compared to the 1.5 mm projectile diameter. Additionally, it results in a greater depth of the compressive residual stress layer and maximum compressive residual stress. The crack initiation sites under two projectile diameters are located below the compressive residual stress layer. The USP treatment introduces compressive residual stress on the surface, inhibiting the initiation of surface cracks, and the deeper compressive residual stress layer offsets the early fatigue failure caused by higher roughness.

Modelling and researching the evolution of stress during arc-directed energy deposition (ADED) hybrid inter-layer hammering

ABSTRACT Hybrid manufacturing of arc-directed energy deposition (ADED) and inter-layer hammering can build components with low detrimental residual stress (RS) and warping. Inter-layer hammering with lower load demand has proved to be a promising technology to improve the microstructure and mechanical properties. In this paper, a finite element model of the ADED hybrid inter-layer hammering was constructed for the first time. The accuracy of the model is evaluated by comparing thermal history, RS, and warping. The results show that the maximum compressive RS -25Mpa appears at 3 mm from the top of the wall after a single inter-layer hammering. The RS of the inspection position is reduced by 74.6% after six layers of hammering compared with the wall manufactured by ADED alone, and low-stress distribution with a value of -30Mpa appears in the range of 7 mm to 15 mm from the substrate surface. The warping of the wall in the building direction was completely suppressed (from 0.21 mm to 0 mm). In addition, the plastic strain introduced by the hammering at the wall top exacerbates the “misfit” between the regions of the wall top, resulting in tensile stress at the wall top.

Studies on residual stress and surface topography after pneumatic shot peening using discrete element method–finite element method coupled model

After pneumatic shot peening, compressive residual stress is induced on the surface of the target, which will improve the fatigue life. During the process, surface roughness is also induced, which may reduce the fatigue life. To achieve the optimum compressive residual stress with the smallest surface roughness, the formation mechanism of the residual stress field and the surface topography are revealed. Then, pneumatic shot peening is simulated by using a discrete element method–finite element method coupled model. Based on the effects of four variables (the incident angle θ, the initial shot velocity v0, the shot radius R) and the mass flow rate rm on five parameters (the equivalent plastic strain, the equivalent stress, the surface compressive residual stress, the maximum compressive residual stress), the surface roughness is investigated. The results show that it induces a residual elastic–plastic strain after the impact of a single shot, which can form a crater and a hemispherical residual stress field. After the impact of many random shots, scattered craters connect with each other, therewith a rough and continuous surface topography is formed. Scattered residual stress fields couple with each other, and a constant residual stress layer with the compressive residual stress in the surface and the tensile residual stress in the subsurface are formed. All five parameters are determined by the residual elastic–plastic strain, which increases as the augment of the normal impact velocity, the shot mass, and the coverage rate. Along with the increase of θ and rm, these five parameters firstly increase and then decrease; with the increase of v0 and R, these five parameters increase. Therefore, reasonable values of θ, v0, R, and rm should be chosen to obtain the optimum compressive residual stress with as small surface roughness as possible.

Mathematical Modeling and Finite Element Analysis of Residual Stress (RS) Field after Multipass Ultrasonic Surface Rolling

In order to achieve the change rule of the induced residual stress (RS) field after multipass ultrasonic surface rolling (USR), a mathematical model of the induced residual stress (RS) field after multipass ultrasonic surface rolling is first established. Then, the coupling mechanisms of the RS field after dual-pass USR and multipass USR are analyzed, respectively. Subsequently, a finite element (FE) model is established, and the influence of the interval between two adjacent rolling paths LS is investigated. Finally, both the mathematical model and the FE model are experimentally verified. The results show that both the mathematical model and the FE model can predict the RS field after multipass USR. Two adjacent RS fields will couple with each other in their overlapping regions. For a relatively small interval LS, the RS field after multipass USR can be fully coupled, so as to form a uniform compressive RS layer. In this study, when LS = 0.05 mm, the values of the surface compressive RS, the maximum compressive RS, the depth of the maximum compressive RS, and the depth of the compressive RS layer reach 426.71 MPa, 676.54 MPa, 0.05 mm, and 0.54 mm, respectively.

Numerical parameter sensitivity analysis of residual stresses induced by deep rolling for a 34CrNiMo6 steel railway axle

To optimise the benefits of the deep-rolling process in the service life context of treated components, the process application must be investigated. In addition to the reduction in surface roughness and near-surface material strengthening, compressive residual stresses are introduced, which are primarily responsible for the increase in service life for components, especially in the case of high-strength steel materials. A numerical parameter sensitivity analysis is performed in order to investigate the introduced residual stresses in detail. For this purpose, a validated deep-rolling simulation model is used, which replicates the deep rolling of a railway axle made of the high-strength steel material 34CrNiMo6. The model is based on an elastic-plastic Chaboche material model parameterised on uniaxial tensile and LCF test results and validated with residual stress measurements. Using this model as a basis, the effect of the main process parameters deep-rolling force, feed rate, friction coefficient, number of overruns, tool geometry, and shaft geometry on the resulting residual stress state are investigated. The results reveal that the deep-rolling force has the most significant influence on the introduced residual stress state and should therefore be highlighted. In the case of applying a deep-rolling force of more than 10 kN, maximum compressive residual stresses of around − 1000 MPa are introduced, and a strong saturating behaviour is shown. Maximum compensating tensile residual stresses of + 100 MPa occur below the surface. The main influence of the deep-rolling force is the effective depth achieved, which is determined by the depth of the zero crossing. This varies from 1 mm with an applied force of 2 kN to more than 3.5 mm with 20 kN. Furthermore, the results are analysed to conclude suggestions for the process’s applicability, and a proposal for an optimised deep-rolling treatment is presented. There multiple deep rolling with decreased deep-rolling forces is used to achieve a comparably optimised residual stress state. In summary, with the presented results, a contribution to a deeper understanding of the deep-rolling process can be achieved; the influence of the most important process parameters on the residual stress in-depth profiles is established; an optimisation proposal is presented; and correlations are found. Thus, the base work for further fatigue strength assessments and the optimisation of the deep-rolling process regarding the increase of service is laid.

Pre-mixed abrasive waterjet peening with post-low stress milling process and the effect of process parameters on the surface integrity of TC11 titanium alloy

Pre-mixed abrasive waterjet peening (PAWJP) is progressively gaining traction in enhancing metal materials’ surface integrity and mechanical behavior. To avoid the disadvantage of PAWJP in the application, a hybrid manufacturing method of pre-mixed abrasive waterjet peening with post-low stress milling (PAWJP-LSM) is proposed and studied experimentally. The principle of PAWJP-LSM was first introduced. Subsequently, the effect of the PAWJP-LSM parameters (i.e., abrasive type, traverse speed, nozzle inlet pressure, and removal amount) on the surface integrity of TC11 titanium alloy and its variation trend were systematically investigated. Results show that the specimen treated with PAWJP using different process parameters formed a PAWJP treatment area with a strengthening depth of 6–275 μm. The minimum surface roughness obtained by PAWJP was 0.727 μm. The maximum surface microhardness significantly increased to approximately 516.3 HV from 402.8 HV, with a maximum micro-hardness rate of 28.2 % and a maximum work hardening depth of 225 μm. The surface compressive residual stress (CRS) induced by PAWJP ranged from −97 to −322 MPa, with a maximum CRS exceeding −890 MPa and a maximum CRS layer thickness of 305 μm. The surface integrity of PAWJP-LSM is further enhanced compared to PAWJP, resulting in a 98.9 % reduction in minimum surface roughness and a 73.7 % reduction compared to the as-received surface roughness. Additionally, PAWJP-LSM exhibited a 98.9 % increase in surface CRS and a 19.4 % increase in maximum CRS. Moreover, the fatigue life was significantly improved by 69.4 %, which was 294.5 % higher than that of the as-received specimen. Nanocrystals with an average size of 27.3 nm were formed in the topmost surface. Overall, the PAWJP-LSM method demonstrated significant potential for engineering applications and exhibited substantial value in the surface treatment of TC11 alloy. This study validated the effectiveness of the proposed PAWJP-LSM method and provided a valuable reference for selecting optimized process parameters.

SEM Analysis and Micro-CT Evaluation of Four Dental Implants after Three Different Mechanical Requests-In Vitro Study.

Implant-supported rehabilitations are an increasingly frequent practice to replace lost teeth. Before clinical application, all implant components should demonstrate suitable durability in laboratory studies, through fatigue tests. The purpose of this in vitro study was to evaluate the integrity and wear of implant components using SEM, and to assess the axial displacement of the implant-abutment assembly by Micro-CT, in different implant connections, after three distinct mechanical requests. Four KLOCKNER implants (external connection SK2 and KL; and internal connection VEGA and ESSENTIAL) were submitted to three different mechanical requests: single tightening, multiple tightening, and multiple tightening and cyclic loading (500 N × 100 cycles). A total of 16 samples were evaluated by SEM, by the X-ray Bragg-Brentano method to obtain residual stresses, and scratch tests were realized for each surface and Micro-CT (4 control samples; 4 single tightening; 4 multiple tightening; 4 multiple tightening and cyclic loading). All dental implants were fabricated with commercially pure titanium (grade 3 titanium). Surface topography and axial displacement of abutment into the implant, from each group, were evaluated by SEM and Micro-CT. In the manufacturing state, implants and abutments revealed minor structural changes and minimal damage from the machining process. The application of the tightening torque and loading was decisive in the appearance and increase in contact marks on the faces of the hexagon of the abutment and the implant. Vega has the maximum compressive residual stress and, as a consequence, higher scratch force. The abutment-implant distances in SK2 and KL samples did not show statistically significant differences, for any of the mechanical demands analyzed. In contrast, statistically significant differences were observed in abutment-implant distance in the internal connection implants Vega and Essential. The application of mechanical compression loads caused deformation and contact marks in all models tested. Only internal connection implants revealed an axial displacement of the abutment into the implant, but at a general level, a clear intrusion of the abutment into the implant could only be confirmed in the Essential model, which obtained its maximal axial displacement with cyclic loading.

Effects of peening duration on surface and wear properties of aircraft graded AA2017 alloy

This investigation addresses the effects of peening duration during SP on surface properties of AA2017 alloy. SP performed with different durations (0, 70, 140 and 210 s) and imparts the modification in the surface region. Alloy strength and structural parameters like crystallite size (D), dislocation density (ρ) microstrain (ε) and lattice constant (a) are increased with SP duration till 140 s. After 210 s, these properties declined due to the effect of softening caused by rise in surface temperature through over peening duration, and exhibited dynamic recovery. Severe plastic deformation developed by SP, created rough surface in all SPed samples and shows responsible for low wettability, high contact angles and low surface energy in comparison with AR sample. The SP140 exhibited maximum hardness (234 ± 7.1 HV) and maximum residual compressive stress (RCS) (−51 MPa) as compared with that of AR sample shown 70 ± 2.1 HV and 20 MPa respectively. Also, the cross-sectional measurements over a thickness of 200 μm confirmed their improvement. These results favoured for SP140 sample to yield lower wear rate about 0.776 mm3/ KN-m compared to AR sample (1.046 mm3/ KN-m). Further increase in shot peening duration to 210 s induces softened layer by rise in surface temperature and presence of Cu as major alloying element in AA2017 exhibits superior thermal conductivity and resulted in detrimental effect on wear resistance. The combination of several factors such as structural parameters, RCS and hardness in the surface region of SP140 sample are responsible to develop the wear resistance of AA2017 alloy.

Analysis of the sequentially coupled thermal–mechanical and cladding geometry of a Ni60A-25 %WC laser cladding composite coating

In this research, a three-dimensional (3D) transient finite element model based on a sequentially coupled thermal–mechanical analysis (SCTMA) is proposed to simulate the evolution of the temperature field and stress field as well as the cladding geometry of the Ni60A-25 % WC laser cladding composite coating. Based on the thermo-physical properties of Ni60A-25 % WC powder and the design of the double ellipsoidal heat source model, a 3D finite element model of double-layer laser cladding with two channels is established. The evolution of the temperature field and the residual stress field at different laser process parameters are investigated to evaluate the quality of the cladding layer. The impact of different laser cladding process parameters on the cladding dimensions is investigated. The dimensions of the simulated molten pool are analyzed by fitting a polynomial curve. The simulation results show that the laser power is proportional to the temperature, and the temperature growth rate of the coating is significantly higher than that of the substrate. The scanning speed is inversely proportional to the temperature. The maximum temperature of the cladding is 1.5 times the maximum temperature of the substrate. The temperature growth rate of the cladding layer is twice that of the substrate. Due to the asymmetry of the heat source in the multi-pass cladding process, the laser energy absorption rate is not the same on both sides of the melted layer. The double ellipsoidal heat source model has a larger diffusion range in the un-melted powder, resulting in asymmetry in the width direction of the cladding layer. The analysis of the residual stresses in the cladding layer shows that the residual compressive stresses in all paths increase with the increasing laser power. The normal x residual compressive stress in the coating and the maximum residual compressive stress occur at the end of the laser beam scan. The residual compressive stress in all paths decreases as the scanning speed increases. The results show that the dimensions of the molten pool are proportional to the laser power and inversely proportional to the scanning speed. The cladding geometry can be calculated with polynomial fitting equations at a selected laser power (500 W–2800 W) and scanning speed (1 mm/s–8 mm/s). The error analysis of the simulation and the experimental results can validate the proposed finite element simulation model. The error in the molten pool size is less than 20 % for the simulation and experimental results.

Development of Maximum Residual Stress Prediction Technique for Shot-Peened Specimen Using Rayleigh Wave Dispersion Data Based on Convolutional Neural Network

Shot peening is a surface treatment process that improves the fatigue life of a material and suppresses cracks by generating residual stress on the surface. The injected small shots create a compressive residual stress layer on the material’s surface. Maximum compressive residual stress occurs at a certain depth, and tensile residual stress gradually occurs as the depth increases. This process is primarily used for nickel-based superalloy steel materials in certain environments, such as the aerospace industry and nuclear power fields. To prevent such a severe accident due to the high-temperature and high-pressure environment, evaluating the residual stress of shot-peened materials is essential in evaluating the soundness of the material. Representative methods for evaluating residual stress include perforation strain gauge analysis, X-ray diffraction (XRD), and ultrasonic testing. Among them, ultrasonic testing is a representative, non-destructive evaluation method, and residual stress can be estimated using a Rayleigh wave. Therefore, in this study, the maximum compressive residual stress value of the peened Inconel 718 specimen was predicted using a prediction convolutional neural network (CNN) based on the relationship between Rayleigh wave dispersion and stress distribution on the specimen. By analyzing the residual stress distribution in the depth direction generated in the model from various studies in the literature, 173 residual stress distributions were generated using the Gaussian function and factorial design approach. The distribution generated using the relationship was converted into 173 Rayleigh wave dispersion data to be used as a database for the CNN model. The CNN model was learned through this database, and performance was verified using validation data. The adopted Rayleigh wave dispersion and convolutional neural network procedures demonstrate the ability to predict the maximum compressive residual stress in the peened specimen.

A simulation modeling methodology considering random multiple shots for shot peening process

Abstract Shot peening (SP) process is a typical surface strengthening process for metal and metal matrix composites, which can significantly improve the fatigue life and strength. The traditional SP simulation model falls short as it only takes into account one or a few shots, proving insufficient for accurately simulating the entire impact process involving hundreds of shots. In this study, a random multiple shots simulation modeling methodology with hundreds of random shots is proposed to simulate the impact process of SP. In order to reduce the simulation error, the random function Rand of MATLAB is used to generate the shot distributions many times, and the shot distribution closest to the average number is selected and the three-dimension parametric explicit dynamics numerical simulation model is built using ABAQUS software. Orthogonal experiments are carried out to investigate the influences of shot diameter, incident impact velocity, and angle on the residual stress distribution, roughness, and specimen deformation. Results showed that the average relative errors of maximum residual compressive stress, roughness, and deformation of specimen between simulation model and experimental value are 30.99, 16.14, and 16.73%, respectively. The primary factors affecting residual stress and deformation is shot diameter, and the main factor affecting roughness is impact velocity.