Laser shock processing of aluminium alloys. Application to high cycle fatigue behaviour

Subjecting target metallic samples to a very short pulse (about 20 ns) of intense (GW cm⁻²) laser light generates, through a surface plasma, a high-pressure stress wave propagating to the first millimetre in depth, which is commonly called laser shock processing (LSP). The purpose of this work was to evaluate the role of this novel process on the cyclic properties of A356, Al12Si and 7075 aluminium alloys. Major contributors to the fatigue performance improvements were investigated in order to determine the optimum shock conditions. These were mainly compressive residual stress (RS) levels for which a large range of incident shock conditions was performed. We showed that stress levels were very sensitive to the laser fluence and the number of local impacts, and experimental RS measurements were found to be in good agreement with analytical modelling results. In comparison, a conventional shot peening (SP) treatment was found to lead to higher surface hardening and RS levels, but with a very detrimental roughening not observed after LSP. High cycle (10⁷) fatigue tests carried out on laser- processed, shot-peened and untreated notched samples illustrated the efficiency of LSP as a new, promising method to improve the fatigue limits σ_D of structures, especially in comparison with enhancements displayed by SP (+22% vs. +10%). According to crack detection electric measurements, fatigue performance improvements with LSP mainly occurred during the crack initiation stage.