Wear and friction of 6061-T6 aluminum alloy treated by laser shock processing

Laser shock processing (LSP) is becoming an important surface treatment to induce a compressive residual stress field, which improves fatigue and fracture properties of components. In this work, we examine the effect of laser shock processing on the wear and friction behavior of 6061-T6 aluminum alloy. Wear rate and friction coefficient evolution are investigated for different process parameters of LSP. Roll-on-flat tribometer is used with different loading conditions. Hardness and residual stresses are assessed as well. It is observed that wear rate decreases as pulse density increases; this is explained in light of residual stress distribution.     

激光冲击钛合金板料的有限元模拟

激光冲击强化技术（LSP）是一种新型的表面处理技术,它利用激光冲击波作用靶材表面而产生残余压应力场.通过有限元软件模拟（FEM）可以分析激光冲击强化处理后靶材的残余压应力场分布,分析材料表面和深度方向的残余应力场的分布情况.先分析了材料的本构模型、激光冲击波的峰值压力的计算、有限元单元类型的选取、边界条件的处理等条件;再通过有限元软件ABAQUS对激光冲击TC4钛合金板料进行了数值模拟,分析了残余应力场的分布特点.     

FEM of residual stress and surface displacement of a single shot in high repetition laser shock peening on biodegradable magnesium implant

Laser shock peening (LSP) is one of the prominent surface processing techniques to improve the mechanical characteristics by inducing compressive residual stress on the specimen surface. Generally, LSP is performed using high energy, low repetition pulsed laser. Recently, High repetition laser shock peening (HRLSP) on biodegradable magnesium alloys has been reported. Increased speed and reduced operating costs are the key highlights of HRLSP. This work is aimed towards understanding of the residual stress profile beneath the specimen surface, where a Finite element method (FEM) has been proposed to show the ability of a tightly focussed nanosecond laser pulse for peening magnesium. The depth of maximum compressive residual stress of 48 MPa at 28 mm beneath surface was the result of the simulation. Also the Von Misses stress was analytically found to be 31.5 MPa, which is similar to the value from FEM at 30 MPa. Furthermore, the plastic displacement of FEM at 4.02 µm compares reasonably well with the experimental result at 3.698 µm, thereby validating the Finite element model. If increase in CRS can be created by single shot of laser pulse, it can be concluded that the same can be done beneath the entire magnesium surface using appropriate scanning protocols.

     

Effects on mechanical properties in electron beam welding of TC4 alloy by laser shock processing

The surface of TC4 titanium alloy welding line by electron beam welding (EBW) was processed by high power Q-switched and repetition-rate Nd: glass laser. Effects of laser power and spot diameter on residual stress and microhardness of the TC4 alloy welding line by laser shock processing (LSP) have been analyzed. Results show that residual stresses almost do not change as laser power is 45.9 J, spot diameter is ϕ9 mm; While laser power is 45.9 J, spot diameter less than ϕ3 mm, the distribution of residual stress in welding line occurs obvious variation, which residual stress increase obviously with spot diameter decrease. When power density is bigger than 1.8 × 10¹⁰ W/cm², residual stresses of electron beam welding line occur change by LSP, which improve obviously residual stress distribution; while laser power is bigger than 1.2 × 10¹⁰ W/cm², the surface micro-hardness of electron beam welding line occurs change by LSP, which improve obviously micro-hardness distribution. Mechanical properties of TC4 titanium alloy welding line will be improved by LSP, which provides experimental foundation for further controlling the distributions of residual stress and micro-hardness during laser shock processing. __________ Translated from Journal of Jiangsu University (Natural Science), 2006, 27(3): 207–210 [译自: 江苏大学学报 (自然科学版)]     

Effects of simulation parameters on residual stresses for laser shock peening finite element analysis

By using finite element analysis, we proposed an applicable finite element method of laser shock peening (LSP) and discussed various parameters, such as solution time, stability limit, dynamic yield stress, peak pressure, pressure pulse duration, laser spot size, and multiple LSP. The effects of parameters related to the finite element simulation of the LSP process on the residual stresses of 35CD4 30HRC steel alloy are discussed. Parametric sensitivity analyses were performed to establish the optimum processing variables of the LSP process. In addition, we evaluated the effects of initial residual stress, such as welding-induced residual stress field.     

Effect of input variability on the quality of laser shock processing

Laser shock processing (LSP) involves high-energy laser radiation combined with suitable overlays to generate high-pressure pulses on the surface of the metal. The stress wave generated due to high pressure pulses propagates into the material causing the surface layer to yield and plastically deform, and thereby, develop a significant residual compressive stress in the surface region of the substrate material. The developed compressive stress field is beneficial to improve surface properties such as fatigue, wear, and corrosion. To improve the understanding of the shock hardening process, investigation into the physical processes involved is necessary. In the first part of this paper, the temporal variation in the pressure intensity and spot size is calculated by using a two-dimensional recoil pressure prediction model. Using an explicit non-linear FEA code, ANSYS LS-DYNA, the deformation behavior and residual stresses in the substrate material are predicted. In the second part, a probabilistic approach to the modeling and analysis of LSP is presented in this paper. Various factors that affect the probabilistic performance of the LSP are grouped into categories and a select number of factors known to be significant, for which the variability could be assessed, are modeled as random variables (such as recoil pressure, laser beam spot size, substrate material properties and others). The potential of the probabilistic approach in predicting the structural integrity of the laser-shocked components is addressed.     

Features of Finite Element Modeling of Residual Stresses Arising in Material under Laser Shock-Wave Processing Using the Intrinsic Deformations Method

Laser shock-wave processing of materials is a modern technology for effective processing of metallic materials. In the near-surface region, the processing produces significant compressive residual stresses that contribute to increasing material strength and improving their tribological and operational characteristics. In this work, we performed finite element modeling of the laser shock-wave technology using the intrinsic deformation method. Specifically, using the intrinsic deformation method, we first solved the dynamic problem on the impact of a shock load and determined the distribution of stabilized plastic deformations (so-called “intrinsic deformations”) and then solved the static problem on the elastic response of the system to the intrinsic deformations induced into it. The level of the resulting compressive residual stresses arising upon laser shock-wave processing is determined. The obtained results correlated well with the known experimental data.     

GH742合金激光冲击强化后的表面残余应力

采用X射线衍射法对GH742合金激光冲击强化后的表面残余应力进行了测试,采用云纹干涉结合盲孔法对残余应力随深度的分布进行了测试。结果表明:GH742合金经激光单点冲击后,表面残余压应力最高可达1 180MPa,且残余压应力层深度达到1.2mm;50%光斑搭接率强化后的表面残余压应力约为1 100MPa。     

Study on effect of time parameters of laser shock peening on residual stresses using FE simulation

Laser shock peening (LSP) is the newest and most innovative surface treatment technique. LSP residual stress distribution is affected by many parameters. Of them, the parameters are main factors that determine the convergence of finite element analysis (FEA) and characteristic of pressure pulse of laser system. The parameters, related to the convergence of FE simulation, are stability limit time for the stable convergence of results, and solution time for dynamic analysis. The other parameters, related to characteristics of pressure pulse of laser system, are pressure pulse duration time and laser pulse interval time for multiple LSP. In the present work, we have conducted to confirm the influence of time parameters of LSP system on residual stress results using FEA, and we have also predicted optimized range of time parameters.     

激光冲击强化对TC4钛合金单面修饰激光焊接接头疲劳性能的影响

对TC4钛合金单面修饰激光焊接接头进行激光冲击强化,对比强化前后焊接接头的疲劳寿命,在光学显微镜和扫描电镜下观察断口疲劳断裂特征,并从焊接接头的显微硬度、微观组织、残余应力分布等方面综合分析激光冲击强化对TC4钛合金单面修饰激光焊接接头的强化机理。试验结果表明：未强化和强化试样均在焊缝咬边处萌生疲劳裂纹,强化试样疲劳寿命是未强化试样疲劳寿命的3.77~9.15倍,强化试样焊缝咬边处马氏体细化,显微硬度提高,焊缝表面呈残余压应力分布,焊缝咬边处残余压应力达-564.37±9.85MPa。晶粒细化和高幅值残余压应力综合作用下抑制了焊缝咬边处疲劳裂纹的萌生,且增大了裂纹扩展阻力,从而提高了焊接接头疲劳性能。     

Two-sided laser shock processing

The principles of two-sided laser shock processing (LSP) are considered. The differences between two-sided and one-sided laser shock processing are noted. For the example of a thin VT-6 titanium-alloy plate, finite-element modeling is used to investigate the residual stress field when using two-sided LSP. The distribution of surface microhardness is analyzed.     

Influence of laser spot overlap effect on residual stresses during laser-shock-wave processing of materials

Laser-shock-wave processing (LSWP) of materials is an innovative material processing technology in which considerable compressive residual stresses are generated in the surface region and contribute to improved strength and performance parameters. We analyze performance capabilities of lasers operating at higher frequencies and lower energy levels compared to lasers used with traditional LSWP technologies. Finite element modeling of compressive residual stresses at different stages of laser spot overlap for BT-6 titanium alloys is carried out. The results are compared with the known experimental data. It is shown that they are correlate well with each other.     

钛合金激光冲击强化层的残余应力及显微组织

对TC6钛合金进行了激光冲击强化(LSP),对强化层的残余应力分布进行了测试,应用透射电子显微镜对强化层的显微组织进行了观察。结果表明:TC6钛合金LSP的最佳功率密度为4GW.cm-2,LSP能在材料表层产生高的残余压应力场,表面残余压应力可达530.4 MPa;LSP可在钛合金表层产生高密度位错和纳米晶,纳米晶尺寸在10～100nm。     

Fretting fatigue of laser shock peened Ti-6Al-4V

The objective of this paper is to examine fretting fatigue of laser shock peened (LSP) titanium to quantify the influence of LSP on fretting fatigue life. Contact conditions such as loads and pad geometry are chosen to generate fretting fatigue stresses similar to those occurring in blade/disk contacts in gas turbine engines. LSP treated specimens attained 5-, 10- and 25-fold increase in lives compared to untreated specimens. Metallography of the contact area and fractographic analysis of worn pads detail the fretting behavior of LSP treated specimens.     

Residual stress behaviors induced by laser peening along the edge of curved models

Laser peening (LP) induces high-magnitude compressive residual stresses in a small region of a component. The compressive residual stresses cause plastic deformation that is resistant to fatigue fracture. Fatigue cracks are generally nucleated at critical areas, and LP is applied for those regions so as to delay the crack initiation. Many critical regions are located on the edge of the curved portion of structures because of stress concentration effects. Several investigations that are available for straight components may not give meaningful guidelines for peening curved components. Therefore, in this paper, we investigate residual stress behaviors induced by LP along the edge of curved models. Three curved models that have different curvatures are investigated for peening performance. Two types of peening configurations, which are simultaneous corner shot and sequential corner shots, are considered in order to obtain compressive residual stresses along an edge. LP simulations of multiple shots are performed to identify overlapping effects on the edge portion of a curved model. In addition, the uncertainty calculation of residual stress induced by LP considering laser pulse duration is performed.     

Optimization of peened-surface laser shock conditions by method of finite element and technique of design of experiments

This paper presents a numerical simulation of the laser shock peening (LSP) process using the finite element method. The majority of controlling parameters of the LSP process have been taken into account. The LSP loading has been characterized by the use of a repetitive time Gaussian increment pressure applied uniformly at a circular impacted zone. The utilized model of the treated material behaviour law is the Johnson-Cook’s visco-elastic-plastic coupled with damage. The proposed model leads to determine the LSP surface modifications: (i) the in-depth residual stresses, (ii) the induced plastic strains and (iii) the superficial damage. These modifications can be significantly induced in few cases, particularly when the operating conditions are not well optimized. An application is carried out on the laser peened titanium aero-engine super alloy Ti-6Al-4V. A satisfactory correlation between the computed and experimental results is observed. Also, it is noted that the computed superficial damage values increase with the growth of the maximal peak pressure of the laser spot, which are physically consistent. Otherwise, in order to optimize the laser peening operating conditions, a design of experiments is established. It allows having surface-response relationships between the operating parameters and the three announced induced effects.     

激光冲击强化效果的控制及人工神经网络预报研究

对激光冲击强化过程中激光参数的选择进行了优化。提出了基于人工神经网络的控制激光冲击强化效果的新方法，引入神经网络对试件经激光冲击后的表面质量类型进行识别。对2024T62铝合金的研究及试验表明，采用该方法能够有效地提高合格试件的成品率。     

Laser shock wave treatment of polycrystalline diamond tool and nanodiamond powder compact

Laser shock processing (LSP) of polycrystalline diamond (PCD) tools and nanodiamond powder compacts was conducted using a 1,064-nm Q-switched Nd:YAG laser at peak power densities in the range of 4 to 18 GW/cm² and pulse repetition rates of 1 to 10 Hz. The PCD tools were directly procured from the tool manufacturer while nanodiamond powder compacts were prepared in the laboratory by cold die press forming and annealing using a powder mixture of nanodiamond, 8 wt.% cobalt, and 10 wt.% agar–agar as the binder. The samples were characterized by Raman spectroscopy, scanning electron microscopy, micro-indentation, and optical profilometer. Results indicate that LSP induced diamond purification, inhomogeneity of phases in PCD, densification in nanodiamond compact, phase transition to various amounts of sp³ and sp² carbon forms, and an increase in hardness and surface roughness.     

激光喷丸技术及其应用

激光喷丸技术是一项新技术，它是用短脉冲（ns级）的强激光辐照在表面覆盖着能量吸收层和约束层的材料上产生冲击波，当激光冲击波诱导的应力波的峰值超过材料的动态屈服极限时，材料的表层将会发生塑性变形，不可回复的塑性变形导致靶材内残余应力的产生。激光喷丸的效果与脉冲的能量、光斑直径的大小、材料的力学性能等因素有关。激光喷丸不仅可以对材料表面进行改性，还可实现板材的塑性成形，并且表面留有有益残余的压缩应力，从而降低了材料的疲劳断裂和应力腐蚀的比率和延长其疲劳寿命。文章简要介绍了该技术在发达国家的应用，也指出该技术在我国走向实用化阶段必须要解决的关键问题。     

Effects of laser shock processing on mechanical properties of laser welded ANSI 304 stainless steel joint

With the rapid development of engineering component with integration,high-speed and multi-parameter,traditional techniques haven’t met practical needs in extreme service environment.Laser welding,a new welding technology,has been widely used.However,it would generate the drop of mechanical properties for laser welded joint due to its thermal effect.Laser shock processing(LSP) is one of the most effective methods to improve the mechanical properties of laser welded ANSI 304 stainless steel joint.In this paper,the effects of LSP on the mechanical properties of laser welded ANSI 304 stainless steel joint have been investigated.The welded joint on the front of the tensile samples is treated by LSP impacts,and the overlapping rate of the laser spot is 50%.The tensile test of the laser welded joint with and without LSP impacts is carried out,and the fracture morphology of the tensile samples is analyzed by scanning electron microscope(SEM).Compared with the yield strength of 11.70 kN,the tensile strength of 37.66 kN,the yield-to-tensile strength ratio of 0.310 7,the elongation of 25.20%,the area reduction of 32.68% and the elastic modulus of 13 063.876 MPa,the corresponding values after LSP impacts are 14.25 kN,38.74 kN,0.367 8,26.58%,42.29% and 14 754.394 MPa,respectively.Through LSP impacts,the increasing ratio of the yield strength and tensile strength are 121.79% and 102.87%,respectively;the elongation and area reduction are improved by 5.48% and 29.38%,respectively.By comparing with coarse fracture surface of the welded joint,the delamination splitting with some cracks in the sharp corner of the welded joint and asymmetric dimples,LSP can cause brighter fracture surface,and finer and more uniform dimples.Finally,the schematic illustration of dimple formation with LSP is clearly described.The proposed research ensures that the LSP technology can clearly improve the yield strength,tensile strength,yield-to-tensile strength ratio,elongation,area reduction and elastic modulus of the welded joint.The enhancement mechanism of LSP on laser welded ANSI 304 stainless steel joint is mainly due to the fact that the refined and uniform dimples effectively delay the fracture of laser welded joints.