Peened Surface Research Articles

Effects of Surface Peening on Residual Stress and Microstructure of Nickel-base Alloy 182 and 52 M Welds

Effects of Surface Peening on Residual Stress and Microstructure of Nickel-base Alloy 182 and 52 M Welds

Correlation between shot peening coverage and surface microstructural evolution in AISI 9310 steel: An EBSD and surface morphology analysis

In this study, martensitic high-strength steel serves as the subject of investigation, with both conventional and severe shot peening experiments being conducted. The coverage levels for conventional shot peening (CSP) are set at 100 % and 200 %, while severe shot peening (SSP) sees levels of 800 % and 1200 %. For the first time, the use of kernel average misorientation (KAM) enables the calculation of geometrically necessary dislocation (GND) density after peening, facilitating the study of GND density distribution across different coverage and offering a method for the visual assessment of peening degree. Results reveal that, under CSP, the gradient distribution of grain size is relatively uniform, whereas SSP leads to a pronounced gradient in grain size distribution. Taking into account the heterogeneous distribution of the initial material microstructure, a gradient in grain size from the surface to the interior of the material will appear after the coverage reaches a certain value, which is 400 % for AISI 9310 steel. Compared with CSP, SSP will further reduce the surface roughness Sa and improve the surface quality. The research presented further understands the relationship between shot peening process parameters and martensitic steel microstructure, providing an important reference for revealing the strengthening mechanism and selecting reasonable process parameters.

Validation of Hole-Drilling Residual Stress Measurements in Workpieces of Various Thickness

BackgroundA recent revision to the ASTM E837 standard for near-surface residual stress measurement by the hole-drilling method describes a new thickness-dependent stress calculation procedure applicable to “thin” and “intermediate” workpieces for which strain versus depth response depends on workpiece thickness. This new calculation procedure differs from that of the prior standard, which applies only to thick workpieces with strain versus depth response independent of thickness.ObjectiveHerein we assess the new calculation procedures by performing hole-drilling residual stress measurements in samples with a range of thickness.MethodsNear-surface residual stress is measured in a thick aluminum plate containing near-surface residual stress from a uniform shot peening treatment, and in samples of different thickness removed from the plate at the peened surface. A finite element (FE) model is used to assess consistency between measured residual stress across the range of sample thickness.ResultsMeasured residual stress varies with sample thickness, with thinner samples exhibiting smaller near-surface compressive stress and a larger gradient of subsurface stress. These trends are consistent with both observed bending (curvature) of the removed samples and the trend in FE-calculated expected residual stress. The measured and expected residual stresses are in good agreement for samples of intermediate thickness, but the agreement decreases with sample thickness. Measured residual stress is invariant with gage circle diameter.ConclusionThe new thickness-dependent stress calculation procedure for hole-drilling provides meaningful improvement compared to thick-workpiece calculations.

Optimization of Laser Cladding Parameters for High-Entropy Alloy-Reinforced 316L Stainless-Steel via Grey Relational Analysis

Laser cladding technology serves as a pivotal technique in industrial production, especially in the realms of additive manufacturing, surface enhancement, coating preparation, and the repair of part surfaces. This study investigates the influence of metal powder composition and processing parameters on laser cladding coatings utilizing the Taguchi orthogonal experimental design method. To optimize the laser cladding parameters, multi-response grey relational analysis (GRA) was employed, aiming to improve both the microhardness and the overall quality of the coatings. The optimal parameter combinations identified through GRA were subsequently validated through experimental tests. The results reveal that the microhardness and quality of the coatings are substantially influenced by several critical factors, including the powder feed rate, laser power, high-entropy alloy (HEA) addition rate, scanning speed, and substrate tilt angle. Specifically, the powder feed rate exerts the most significant effect on the microhardness, dilution rate, and average contact angle. In contrast, laser power primarily impacts the mean contact angle difference. The HEA addition rate notably affects the mean contact angle difference, while the scanning speed affects the microhardness and the substrate tilt angle influences the average contact angle. The results of the validation experiment showed a deviation of only 0.95% from the predicted values, underscoring the efficacy of the grey relational analysis (GRA) in optimizing the laser cladding process parameters. The methodology presented in this paper can be applied to determine the ideal processing parameters for multi-response laser cladding processes, encompassing applications such as surface peening and surface repair.

Effect of peening treatment on fatigue strength of welded joints of aged steel

This study experimentally investigates the effect of peening treatment on the fatigue strength of welded joints of aged steel. Fatigue tests were conducted on T-shaped fillet welded joints made from three different types of aged steel under three-point bending loading conditions. To reveal fatigue strength improvement mechanism, residual stress measurement, hardness measurement, and metallographic analysis were performed at the weld toe for both as-weld and peened specimens. Fractured surfaces were examined to identify crack initiation sites and propagation. The findings reveal that peening treatment introduces compressive residual stress on the peened surface of welded joints of aged steel equal to or higher than conventional steel welded joints. Higher improvement of hardness was observed in the near surface of the peened welded joints of aged steel, and the improvement continued up to around the zero crossing points of the residual stress distribution. Additionally, peening treatment might refine near-surface grains of aged steel welded toe similar to conventional steel. The fatigue strength improvement effect of the peening treatment was the same for aged steel as conventional one. Cracks were observed on the peened surface of the aged steel due to over-peening treatment. However, it doesn't affect the fatigue strength improvement of the welded joints of aged steel. In summary, it can be said that peening treatment can improve fatigue strength of welded joints of aged steel in the same manner of conventional steel.

Effect of surface high-density twinned structure on the fatigue crack initiation of Ti–6Al–4V

Fatigue crack initiation sites would transfer from surface to subsurface of metal specimens through shot peening (SP) or laser shock surface strengthening. This phenomenon is typically attributed to the introduction of compressive residual stress on the surface of the specimen during the surface strengthening process. In this study, Ti–6Al–4V specimens featuring a high-density twinned structure on their surfaces, which eliminated compressive residual stress, were fabricated. Fatigue test result revealed that fatigue crack initiation sites in specimens with twinned structures were predominantly located in the subsurface, near the junction area between the twinned structure and the matrix. This phenomenon was accompanied by an increase in fatigue life. The microstructural features in the fatigue crack source were analyzed using focused ion beam (FIB) coupled with electron backscattered diffraction (EBSD) and transmission electron microscopy (TEM). It was observed that primary crack formed in badly oriented grains that are difficult to initiate dislocation slip according to the Schmid factor (SF). Nonetheless, TEM observations revealed the activation of basal <a> dislocations in these grains, potentially leading to crack nucleation along basal slip bands and subsequent propagation along the basal plane. Our results suggest that a high-density twin structure on the surface can enhance the fatigue strength of Ti–6Al–4V by transferring the fatigue crack source to the subsurface.

Microstructure evolution and surface strengthening behavior of 300 M ultrahigh strength steel under engineered surface treatments

In this work, the most efficient and common engineered surface treatments identified as shot peening (SP), laser shock peening (LSP) and ultrasonic surface rolling process (USRP) were utilized to impact the 300 M ultrahigh strength steel. The microstructure evolution and surface strengthening behavior were carefully characterized and compared for the 300 M steel with various treatments. Besides, the underlying mechanisms for difference in grain refinement and surface mechanical properties by the arranged surface modification are revealed. The results indicate that a gradient structure with nano-grains at the top surface appears on the SP, LSP and USRP treated samples. The process of repeated impacts of SP in different directions leads to activation of multiple slip systems, which thus causes severe refined grains and dense dislocation activities associated with dislocation tangles, dislocation walls and blocking. A great variety of strikes per unit area by USRP results in higher plastic deformation compared to SP where numerous dislocation cells and deformation bands were generated. In contrast to SP and USRP, fewer slip systems are activated in LSP due to the short duration time which thus leads to the thinnest refined grain layer and more planar dislocation structures. The combination of low plastic work and lack of refined grains leads to lowest full width at half maximum (FWHM) in case of LSP samples whereas high FWHM comes from both fine grain size and dislocations in SP. The grain refinement and plastic work contributes to an increase of microhardness and compressive residual stress for the SP, LSP and USRP samples. To be clear, SP leads to a higher magnitude of hardness and compressive residual stress on the topmost surface while LSP causes a larger depth due to that shock wave in LSP influences material to much greater depth. Besides, the decomposition and redistribution of carbides are also noticed on the surface layer after the surface treatments with very high strain rate where numerous dislocations accumulate at the border of the carbides and slip trace is also observed within the carbides.

Oxidation behaviour of austenitic stainless steel 304HCu in Advanced Ultra Supercritical (AUSC) steam and the efficacy of shot-peening treatment

Effect of shot-peening on the oxidation behaviour of alloy 304HCu in controlled advanced ultra-supercritical (AUSC) steam at 650 ◦C, 31 MPa for 600 h was investigated. Non-shot peened surfaces form thick Fe-rich oxides, undergo internal oxidation, and suffer oxide spallation sooner than those reported in literature. Shot-peened surfaces form a thin, external chromia scale with Mn(Cr,Fe)2O4 and MnCr2O4 spinels growing above and below it respectively. Shot-peening enhances Cr and Mn diffusivity through grain refinement and increased dislocation density, which aids in resisting chromia scale breakdown, eliminating iron oxides, and preventing oxide spallation. Oxide growth mechanism in AUSC steam is discussed.

Hydrogen charging can relax compressive residual stresses caused by shot peening

Surface engineering to generate compressive stresses via processes such as shot peening is commonly employed to mitigate fracture or fatigue failures in metallic systems. Localized plastic deformation is used to generate the generally biaxial compressive elastic stresses. This study examined the residual stress conditions and local mechanical performance of medium carbon steel in a quenched and tempered state. Electrolytic hydrogen charging of peened samples led to a permanent reduction in the compressive surface stress while concurrently hardening the surface. Slight changes in elastic modulus when solute hydrogen was present could not explain the resulting change in the measured residual stress; a reduction in X-ray peak breadth suggests that the combined effects of elastic stresses and solute hydrogen caused local dislocation annihilation and re-organization of the dislocation structure in the severe plastically deformed layer, leading to a lower magnitude and shallower depth of compressive residual stress on the peened surface after hydrogen charging.

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 numerical method for generation of shot peened surfaces

Shot peening is a widely utilized surface modification technique, and the surface morphology of the treated materials plays a crucial role in determining their friction and fatigue properties. Surface morphology generation is a pivotal process in simulating shot-peened surface friction and other performance characteristics. However, there are limited available methods for shot-peened surfaces until now. In this paper, we present a method that directly specifies the height probability distribution and power spectrum to generate shot-peened surfaces. Compared to methods that specify height parameters, this method has more flexibility. This approach replaces the traditional Johnson transformation method with an optimization algorithm to generate height data that follows a high probability distribution, while the power spectrum is derived from the Fourier transform of an exponential autocorrelation function. The results show that this approach can generate shot-peened surfaces using any conventional height parameters, with a maximum difference in height parameters between the reconstructed surface and the original surface of no more than 18.63%. Compared to the Johnson transformation method, this method significantly reduces the errors in skewness and kurtosis of the generated surface. It offers rapid surface generation for shot-peened surfaces, leading to significant time and cost savings in experiments.

Evaluation of 3D Printing Orientation on Volume Parameters and Mechanical Properties of As-Build TI64ELI

The discovery of the utility of various titanium alloys as implant biomaterials has resulted in these materials becoming far more popular than other metals in the medical world. However, the production of these materials using additive manufacturing has its own challenges some of those being the surface finish that can be used as an implantology material. As such, the purpose of this study is to evaluate the influence of 3D-printed Ti64ELI on the as-built samples printed at 60°, 90°, and 180° orientations. Such studies are very limited, specifically in the development of the laser shock peening surface modification of dental implants. The study showed that each mechanical test that was performed contributes differently to the printing orientation, e.g., some tests yielded better properties when 180° printing orientation was used, and others had poorer properties when a 180° printing orientation was used. It was observed that 60° testing yielded a micro-hardness value of 349.6, and this value was increased by 0.37% when 90° orientation was measured. The lowest HV value was observed under a 180° orientation with 342.2 HV. The core material volume (Vmc) was 0.05266 mm3/mm2 at a 60° orientation, which increased by 11.48% for the 90° orientation. Furthermore, it was observed that the surface roughness (Sa) at 60° orientation was 43.68 μm. This was further increased by 6% when using the 90° orientation.

Effect of ultrasonic shot peening on microstructure and mechanical properties of GH3230 superalloy during selective laser melt solution heat treatment

Additive manufacturing (AM) is widely used because of its well-known advantages, but there are some disadvantages including microstructure inconsistencies and harmful residual stresses, which can lead to premature part failure. In this study, the microstructure, and mechanical properties of GH3230 alloy processed by AM are changed by a new post-treatment method, which combines thermal solution treatment (ST) and ultrasonic shot peening (USP). The microstructure evolution of GH3230 after ST and USP after ST is investigated experimentally. The experimental results show that equiaxed crystals and M23C6 carbides appear after solution treatment. After ST, USP is performed, and the gradient microstructure is formed perpendicular to the shot peening surface. Dislocation entanglement and grain refinement occur in the plastically deformed layer. In addition, the carbide interacts with the dislocation. After ST, USP can produce a high level of residual compressive stress in the plastic deformation layer. This combination of ST and USP helps to improve the mechanical properties of additive manufactured parts by changing their microstructure and residual stress distribution.

Shot Peening Effect on Sliding Wear in 0.9% NaCl of Additively Manufactured 17-4PH Steel.

The growing demand for modern steels showing corrosion and tribological resistance has led to their increased use in the production of medical devices. This study analyzed the effect of shot peening on wear resistance in 0.9% NaCl solution of 17-4PH steel produced by direct laser metal sintering (DMLS) technology. The study's novelty relies on revealing the effect of shot peening (SP) surface treatment on the wet sliding wear resistance of 17-4PH steel produced with DMLS. Moreover, in the context of 17-4PH steel application for medical devices, the 0.9% NaCl tribological environment were selected, and SP processes were conducted using steel CrNi shot and ceramic (ZrO2) beads. The up-to-date scientific literature has not identified these gaps in the research. DMLS technology makes it possible to obtain products with complex architectures, but it also faces various challenges, including imperfections in the surface layer of products due to the use of 3D printing technology itself. The chemical and phase composition of the materials obtained, Vickers hardness, surface roughness, and microscopic and SEM imaging were investigated. Tribological tests were carried out using the ball-on-disc method, and the surfaces that showed traces of abrasion to identify wear mechanisms were subjected to SEM analysis. The XRD phase analysis indicates that austenite and martensite were found in the post-production state, while a higher martensitic phase content was found in peened samples due to phase transformations. The surface hardness of the peened samples increased by more than double, and the post-treatment roughness increased by 12.8% after peening CrNi steels and decreased by 7.8% after peening ZrO2 relative to the reference surfaces. Roughness has an identifiable effect on sliding wear resistance. Higher roughness promotes material loss. After the SP process, the coefficient of friction increased by 15.5% and 20.7%, while the wear factor (K) decreased by 25.9% and 32.7% for the samples peened with CrNi steels and ZrO2, respectively. Abrasive and adhesive mechanisms were dominant, featured with slight fatigue. The investigation showed a positive effect of SP on the tribological properties of DMSL 17-4PH.

Correlation between the micro-shot peening coverage and surface microstructural evolution and fluoride-induced corrosion behavior in Monel 400 alloy

This study examines the influence of micro-shot peening (MSP) on Monel 400 alloy, focusing on surface microstructural evolution and fluoride-induced corrosion behavior compared to its solution annealed (SAed) counterpart. MSP treatments were conducted at various surface coverages (100%, 200%, 500%, 1000%, 1500%, and 2000%). Characterization encompassed microhardness, surface roughness, grazing incidence x-ray diffraction (GI-XRD), field emission scanning electron microscopy (FE-SEM) with electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM). With increasing the MSP coverage to 2000%, the surface crystallite size decreased from approximately ∼30 µm in the SAed sample to 60 nm. TEM analysis emphasized dislocation slip and formation of dislocation structures as the primary mechanisms for the grain refinement. However, the 2000% coverage exhibited microcrack formation, compromising its hydrofluoric (HF) corrosion resistance. Electrochemical tests revealed severe localized corrosion in all MSP-treated samples except the 1500% coverage, which exhibited a minimum passive current density of 0.2–1.0 µA/cm2. Inductively coupled plasma optical emission spectroscopy (ICP-OES) of immersion solutions showed lower copper and nickel ion concentrations (<150 ppm) in the 1500% MSP-treated sample, indicating its enhanced corrosion resistance. X-ray photoelectron spectroscopy (XPS) identified NiO, NiF2, CuO, CuF2, and Cu(OH)2 phases in SAed and 1500% MSPed samples, with a higher concentration of copper oxide (CuO) in the corrosion film of the 1500% MSP-treated sample, contributing to its superior corrosion resistance.

Ultrasonic Impact Treatment (UIT) combined with powder bed fusion (PBF) process for precipitation hardened martensitic steels

High-strength martensitic stainless steels such as 17–4 PH (SS 17–4 PH) generally exhibit poor ductility and strain-hardening rates. In this study, an Ultrasonic Impact Treatment (UIT) is combined with a powder bed fusion (PBF) manufacturing process with the objective of enhancing the mechanical properties of SS 17–4 PH. UIT is introduced as a surface peening step at regular intervals during the PBF process after depositing a set of predetermined number of layers. The coupon specimens extracted from the build are then subjected to a post-build heat treatment. Then the microstructural and the mechanical properties of these specimens are characterized. The characterizations reveal that the heavy plastic deformation induced by UIT drives microstructural relaxation and recrystallization under heat treatment, reducing defects extensively. The heavy plastic deformation also drives diffusional reversion of the austenite phase during deposition and an inhibition of the martensitic phase transformation during the post-build heat treatment. As a result, the UIT specimens subjected to post-build heat treatment exhibit remarkable enhancement in ductility along with high strength and strain-hardening rate compared to the non-UIT PBF specimens under as-built condition.

Study of the shot peening surface roughness in fretting

Fretting fatigue manifests in mechanical systems exposed to contact forces that vary over time, resulting in premature cracks that can lead to component failure. Shot peening treatment is one of the palliatives to mitigate fretting fatigue problems. Recent studies have noted that the fretting fatigue is also extended by exclusively applying SP to the contact pad surface. This suggests that the improvement in the fatigue live produced by SP comes not only from the compressive residual stresses but also due to the characteristic surface roughness from the SP treatment. For this reason, the main goal of this work is to analyse how the shot peened roughness affects the fretting fatigue life. To do so, a confocal microscope was used to measure various profiles of shot peened pads. Using these profiles, and under fretting loads combination, the contact stress and strain field are calculated, followed by the application of a fatigue model. Finally, the estimated fatigue life is contrasted with empirical data derived from a research published by the authors. The study reveals that the fretting fatigue life is influenced by the surface roughness, although to a lesser extent with respect to residual stresses. Besides, the Smith-Watson-Toper parameter and stress intensity factor were analysed, suggesting that the rough surface primarily affects the initiation phase rather than the propagation phase, as it was expected.

Effect of pulsed femtosecond laser shock peening surface modification on anti-wear failure properties of AISI 9310 gear steel

The wear resistance of gear components significantly influences operational reliability and lifespan of mechanical equipment. Compared with nanosecond time scale laser surface treatment, femtosecond laser shock peening (FLSP) has the advantage of no absorption layer and constraint layer in processing complex geometric structure parts. However, attempts at FLSP for gear materials are quite limited up to now. This paper introduces a methodology employing Pulsed FLSP to enhance the wear resistance of AISI 9310 gear steel. The research delves into the effects of FLSP on the surface morphology, mechanical characteristics, and wear performance of AISI 9310 steel under varying laser energy levels (50 μJ, 100 μJ, 150 μJ, 200 μJ) and pulse spacings (10 μm, 15 μm, 30 μm). The findings reveal that femtosecond laser surface treatment significantly augmented surface microhardness by 9.4 % to 17.4 % and induced a surge in surface residual compressive stress (RCS) by 30.5 % to 103.1 %. Moreover, it introduced a work hardening layer of 150–300 μm in depth direction, resulting in a wear rate reduction ranging from 10.1 % to 61.7 %. The sample treated with 15 μm pulse spacing and 150 μJ laser energy exhibited simultaneously the lowest wear rate and a minimum average coefficient of friction (COF) on 0.47. The advancement in wear resistance is attributed to the synergistic effects of markedly increased surface hardness, gradient hardness in depth direction, and reduced grain size induced by FLSP. A multiple linear regression (MLR) model indicates that deeper work hardening layers are most significant for improving wear resistance, which reduces risk of wear failure.

Effect of process parameters involved in SWJP on surface integrity and biocompatibility characteristics of AZ31B Mg alloy

This study mainly investigates the influence of combined parametric conditions employed in submerged waterjet peening for biomedical applications. On measuring the microhardness and roughness on the peened surface, the finding corresponded directly with the strengthening of subsurface layers and different parametric combinations. The optimum parametric combination was determined by TOPSIS, considering microhardness and surface roughness as input. Under optimal parametric combinations, surface morphology and topography analysis, XRD analysis, corrosion behaviour examination, and cell morphology and viability analysis were studied and compared to unpeened surface. From the experimental results, the water bubbles create impulsive pressure that impacts the AZ31B Mg alloy's surface, promoting plastic deformation in the subsurface, enhancing the surface morphological and topographical characteristics, and making the alloy more suitable for bioimplant manufacture. Following that, these samples underwent an electrochemical corrosion study, which indicates the peened region's corrosion rate was reduced considerably compared to the unpeened region. In the course of biocompatibility analysis, the non-toxic nature of the peened region in the MG63 cell line was observed after 24 and 72 h.

Simultaneous flattening and hardening of laser shock peened Zr-based metallic glass surface by nanosecond laser irradiation in a flowing nitrogen atmosphere

Laser shock peening (LSP) is an ideal surface modification technique which has been extensively applied to improve the room-temperature plasticity of metallic glasses (MGs) by generating extra-deep compressive residual stress region and increasing the free volume content. Nevertheless, after LSP treatment, the surface quality and hardness of MGs are usually impaired simultaneously, which hinders their applications as structural and functional materials. In the current study, an attempt was made to achieve simultaneous flattening and hardening of LSP treated (LSPed) Zr-based MG by nanosecond laser irradiation in a flowing nitrogen atmosphere. The effects of laser power level on the macro- and micro-morphology, chemical composition, surface hardness, and surface roughness (Sa) of the laser-irradiated LSPed MG were comprehensively investigated. It was found that the minor surface defects of the LSPed MGs could be effectively reduced by nanosecond laser irradiation under appropriate laser irradiation parameters, and accordingly, the surface quality was improved (with a maximum reduction in surface roughness (Sa) by 86.3%). Furthermore, the nanoindentation test results indicated that nanosecond laser irradiation at a relatively high laser power of 15.6 W resulted in an impressive improvement (173.9%) in surface hardness of the LSPed MG, which could be attributed to the introduction of hard nitrided phases mainly consisting of Zr3N4. This study provides an insightful understanding of the microstructure changes and surface characteristics of the LSPed MGs after nanosecond laser irradiation in a flowing nitrogen atmosphere, which paves the way for improving the applicability of MGs as structural and functional materials.