先进喷丸表面改性技术研究进展

综述了先进喷丸表面改性技术研究现状及应用,阐述了微粒子喷丸、激光喷丸、超声/高能喷丸、高压水射流喷丸的基本原理,与传统喷丸对比发现,微粒子喷丸可提高材料的耐磨性,激光喷丸可精确控制定位,超声/高能喷丸可实现材料表面纳米化,高压水射流喷丸可承受半柔性冲击并减少应力集中.此外,对各种喷丸技术综合分析并进行对比,认为超声喷丸、复合喷丸(高能-微粒喷丸,激光-机械喷丸)综合性能最佳,并展望了未来应重点开展的工作.     

Improvement of spring fatigue strength by new warm stress double shot peening process

Abstract

Shot peening technology plays a very important role in improving the fatigue strength of springs. In the present paper a new warm stress double shot peening (WSDSP) process developed by the authors is described. The authors have previously proposed a warm stress shot peening (WSSP) process, which is a combination of warm shot peening (WSP) and stress shot peening (SSP). Double shot peening (DSP) has been the method employed most widely for improved fatigue strength to date. The fatigue strengths resulting from these shot peening processes are compared in the present work. The new WSDSP process leads to significant improvement of spring fatigue strength because it includes an additional shot peening stage with small shot size (0.2 mm dia.), elevated temperature (300°C), and stressed condition (735 MPa), all not found in WSSP. After 300 000 cycles, the standard required life span, WSDSP results in a fatigue strength as high as 735 ± 590 MPa. In comparison, DSP gives a fatigue strength of 735 ± 300 MPa and WSSP of 735 ± 500 MPa. The WSDSP treated material gives the highest performance because the use of small shot size for the additional warm stress shot peening increases the compressive residual stress and hardness near the surface, and decreases the surface roughness.     

Shot peening of plasma nitrided steel for fretting fatigue strength enhancement

Abstract

The potential of fretting fatigue strength enhancement by a duplex surface engineering process involving shot peening of plasma nitrided steel, termed duplex SP/PN, is demonstrated. Specimens of 709M40 steel were individually plasma nitrided, shot peened, or duplex SP/PN treated. Fretting fatigue properties of the surface engineered specimens were evaluated. Surface roughness, residual stress, and hardening effect following the various surface treatments were examined and compared. It has been found that the duplex treatment can significantly improve the fretting fatigue strength of the investigated low alloy steel. Under the present testing conditions, the duplex SP/PN treatment increased the fretting fatigue strength (at 10⁷ cycles) of 709M40 steel by more than 70% relative to the nitrided, 120% to the shot peened, and 500% to the untreated steel. The improvement has been explained in terms of the significantly increased surface hardness and compressive residual stress in the near surface region following the duplex SP/PN treatment. By analysing the stress distributions in a shot peened surface, the influence of surface roughness on fretting fatigue strength is also discussed.     

Surface characteristics and fatigue performance of warm shot peened wrought magnesium alloy Mg–9Gd–2Y

Abstract

The surface characteristics and fatigue performance of the warm shot peened Mg–9Gd–2Y alloys were investigated. Compared to conventional shot peening (SP) at room temperature, warm shot peening (WSP) at 240°C induces higher subsurface hardening and larger maximum compressive residual stress in the subsurface of the specimens. The optimum Almen intensity of WSP is 0·15 mm N, whereas it is 0·10 mm N for SP. The main reason is that the surface of warm shot peened specimen is more plastically deformed but less damaged at the optimum Almen intensity due to the increase in plastic deformation ability of the tested alloys at elevated temperature. The fatigue strength of the tested alloy at 10⁷ cycles is increased from 125 to 175 MPa by optimum SP and to 185 MPa by optimum WSP.     

Technical note A study on stress, reflection and double shot peening to inrease compressive residual stress

The technique of shot peening is commonly used to increase the fatigue limit of a steel. However, there are many practical difficulties in applying it to very high HV steel and complicated components. To overcome these problems, the authors proposed two new methods: stress double shot peening and stress reflection double shot peening. Both techniques were applied to quench and tempered steel (QT steel) and induction-heated steel (IH steel). The main results were as follows: (a) by double shot peening, the compressive residual stress near the sample surface was increased considerably; (b) by stress shot peening, the maximum compressive residual stress ( σ _max ) and the surface compressive residual stress ( σ _s ) were greatly increased; (c) by stress double shot peening, very high compressive residual stresses ( σ _max = −1710 MPa and σ _s = −1320 MPa) were successfully introduced into a hard steel (HV = 700); (d) in the new method (stress reflection double shot peening), very high compressive residual stresses ( σ _max = −1760 MPa and σ _s = −1460 MPa) were successfully introduced into a hard steel (HV = 700).     

Survey about effects of shot peening conditions on fatigue performances of Ti–6Al–4V mechanical specimens featured by different cross-section geometries

Abstract

The present article provides a technical survey of the effects of shot peening conditions on the fatigue performance of Ti–6Al–4V specimens representative of the material (and the surface treatment) used in helicopter rotor hubs. As the effects of shot peening on non-plain surfaces have been fairly neglected in the scientific literature, the present work attempts to define the effects of shot peening on different specimens, featuring specific cross-section geometries, namely smooth and sharp edged specimens. Experimental tests also include measurements of the residual stress field caused by shot peening and the definition of the fatigue limit (by means of the ‘staircase method’) for all the tested specimen configurations. The present study proceeds with an optical and scanning electron microscopic investigation of the dynamics and causes of the different fatigue limits associated with the geometrical features. The present study conveys a strong correlation between specimen geometry and shot peening microstructural effects, resulting in different fatigue performances. The present work concludes that, whenever surface treatment is involved in the manufacturing process, the component’s design must be included, in addition to the required geometrical features for the operative conditions, an evaluation of how these provided features might affect the surface treatment outcome.     

矿用圆环链条接链环喷丸后残余应力分析

采用喷丸强度（SPI）为0．41和0．5A／mm两种表面喷丸强化的工艺对矿用圆环链条接链环进行强化处理,使用X-350A型X射线应力测定仪对喷丸强化后的接链环表面的残余应力与（211）晶面的半高宽卢进行测定。结果表明：高的喷丸强度可以得到更高的残余应力值,对接链环表面进行喷丸强化处理可以有效地引入残余压应力,提高接链环的疲劳寿命。     

Influence of shot peening on high-temperature corrosion and corrosion-fatigue of nickel based superalloy 720Li

High-temperature corrosion fatigue, a combination of corrosion with a fatigue cycle, is an emerging generic issue affecting power generation and aero gas turbine engines and has the potential to limit component life. Historically, surface treatments, such as shot peening have been used to improve component life and have been optimised for fatigue response. Research into optimisation of shot peening techniques for hot corrosion and high-temperature corrosion fatigue has shown 6–8A 230H 200% coverage to provide overall optimum performance for nickel-based superalloy 720Li based on the limited data within this study. Utilisation of electron backscatter diffraction techniques, in combination with detailed assessment of corrosion products have been undertaken as part of this work. The resultant cold-work visualisation technique provides a novel method of determining the variation in material properties due to the shot peening process and the interaction with hot corrosion. Through this work it has been shown that all three shot peening outputs must be considered to minimise the effect of corrosion fatigue, the cold work, residual stress and surface roughness. Further opportunity for optimisation has also been identified based on this work.     

Effects of laser peening on the fatigue strength and defect tolerance of aluminum alloy

The effects of laser peening (LP) on the bending fatigue strength of the 7075‐T651 aluminum alloy were investigated. Accordingly, the defect tolerance of the aluminum alloy subjected to LP is discussed on the basis of fracture mechanics. The results indicate that a deeper compressive residual stress was induced by LP compared with the case of shot peening (SP). The fatigue strengths increased when both peening types were used. Semicircular slits with depths less than 0.4 and 0.1 mm were rendered harmless on the basis of the applications of LP and SP, respectively. The apparent threshold stress intensity factor range ΔK_th,ap increased by approximately five and two times owing to LP and SP, respectively. The increase of the ΔK_th,ap was caused by the compressive residual stress induced by the peening. The Kitagawa‐Takahashi diagram of the laser‐peened specimens shows that the defect tolerance of the aluminum alloy was improved by LP.     

Surface Modification of 304 Steel Using Triple-Step Shot Peening

This paper reports the influences of triple-step shot peening (SP) on the microstructure and residual stress evolution for the 304 stainless steel. The microstructure and residual stress were characterized by X-ray diffraction analysis methodology. After triple-step SP, the domain sizes decreased while the dislocation density and compressive residual stress increased as a result of the austenite and martensite in the peening deformed layer. With an increase in depth, the micro-strain for austenite decreased gradually while the micro-strain for martensite increased first, and then decreased.     

Effects of shot peening on fatigue properties of 0Cr13Ni8Mo2Al steel

Abstract

The influence of shot peening on the fatigue properties of 0Cr13Ni8Mo2Al steel has been studied. Changes in surface roughness, surface topography and residual compressive stress field were determined by experiments. The experimental results show that shot peening improves the fatigue property and the fatigue crack sources are pushed to the region beneath the hardened layer. Low Almen intensities should be used when 0Cr13Ni8Mo2Al steel is shot peened because of its sensitiveness to the surface roughness.     

Effect on fatigue performance of shot peened components: An analysis using DOE technique

Shot peening is widely used to improve the fatigue properties of components and structures. Residual stresses, surface roughness and work hardening are the main effects induced in the superficial layer from shot peening, which depend on the correct choice of the peening parameters. Compressive stresses are beneficial in increasing resistance to fatigue failures, corrosion fatigue, stress corrosion cracking, hydrogen assisted cracking, fretting, galling and erosion. In this paper design of experiment (DOE) technique was used in carrying out test, using an air blast type shot peening machine. This investigation examines the effect of process parameters such as pressure, shot size, nozzle distance and the exposure time on the fatigue performance of AISI 1045 and 316L material. After going through confirmation test the analysis reveals the right combination of the parameters for better process control. An ANOVA was carried out to identify significant peening parameters. Expressions correlating fatigue life and the process parameters for both materials were developed, which are useful in predicting fatigue life. This technique could prove beneficial in industries for reduction of performance variation and cost and to increase productivity.     

Effects of Shot‐Peening on Fretting Fatigue Crack Growth Behavior in Ti‐6Al‐4V

Abstract: The effects of shot‐peening on fretting fatigue crack growth behaviour in titanium alloy, Ti‐6A1‐4V were investigated. Three shot‐peening intensities: 4A, 7A and 10A were considered. The analysis involved the fracture mechanics and finite element sub‐modelling technique to estimate crack propagation lives. These computations were supplemented with the experimentally measured total fretting fatigue lives of laboratory specimens to assess the crack initiation lives. Shot‐peening has significant effect on the initiation/propagation phases of fretting fatigue cracks; however this effect depends upon the shot‐peening intensity. The ratio of crack initiation and total life increased while the ratio of the crack propagation and total life decreased with an increase of shot‐peening intensity. Effects of residual compressive stress from shot‐peening on the crack growth behaviour were also investigated. The fretting fatigue crack propagation component of the total life with relaxation increased in comparison to its counterpart without relaxation in each shot‐peened intensity case while the initiation component decreased. Improvement in the fretting fatigue life from the shot‐peening and also with an increase in the shot‐peening intensity appears to be not always due to increase in the crack initiation resistance from shot‐peened induced residual compressive stress.     

Investigation on the residual stress and microstructure of (TiB + TiC)/Ti-6Al-4V composite after shot peening

Titanium matrix composites reinforced with TiB and TiC are fabricated by in situ technology. The distribution of residual stresses and microstructure are investigated after shot peening. The domain sizes and the microstrain of surface deformation layers are calculated from the full width at half maximum of Ti (2 1 3) peak. The results reveal that both compressive residual stresses and microhardness increase with the improvement of shot peening intensity in the surface deformation layers. And the domain sizes are refined and the microstrain become severely in surface layers after shot peening. In the progress of investigation, it is found that these variations are influenced by both the volume percentages of reinforcements and shot peening intensities. Comparing to the reinforcements, the effects of SP intensities were distinct and dominate.     

Effect of Shot Peening Parameters to Residual Stress Profiles and Barkhausen Noise

The production of gear components includes numerous manufacturing operations which are carried out to ensure proper surface characteristics of components to deal with wear and fatigue. Surface shot peening is one way to increase the compressive residual stresses on the surface and thus ensure better wear and fatigue resistance. An experimental plan for shot peening was conducted to produce samples with varying surface characteristics. Residual stress profile and Barkhausen noise measurements were carried out for the samples. The objective of the study was to evaluate the interactions between the shot peening parameters studied, the residual stress profiles and the Barkhausen noise measurements. A multivariable regression analysis was applied for the task. Some remarkable correlations were found between the shot peening parameters, residual stress profile and Barkhausen noise features. The most important finding was that when the shot peening intensity was high enough, over 0.5 mmA, it dominated the shot peening coverage density parameter and thus no correlations could be gained. On the other hand, if the intensity parameter was lower than the limit of 0.5 mmA, the correlation between residual stress and Barkhausen noise measurements was remarkable. This means that the surface Barkhausen noise measurements could be used for the evaluation of the stress gradient in the shot peening process.     

Shot peening process: modelling,verification, and optimisation

Abstract

The paper describes the shot peening process and derives expressions for the indentation of surfaces by single shot impacts. These are supplemented by analysis of surface coverage and an assessment of the sources of residual stress. The high strain rate mechanical properties of 5052 aluminium alloy, 316 stainless steel and Ti–6Al–4V have been measured for use in a FEM/DEM simulation model. Specimens of these alloys have also been shot peened and examination of their surfaces has allowed an estimate of shot velocity to be made. Simulations of the process have been compared with diffraction scanning measurements of residual stress profiles and the correlation between the data is good. Procedures for optimising the shot peening process have been proposed.     

Crack incubation in shot peened AA7050 and mechanism for fatigue enhancement

Shot peening is a dynamic cold‐working process involving the impingement of peening media onto a substrate surface. Shot peening is commonly used as a surface treatment technique within the aerospace industry during manufacturing to improve fatigue performance of structural components. The compressive residual stress induced during shot peening results in fatigue crack growth retardation, improving the performance of shot‐peened components. However, shot peening is a compromise between the benefit of inducing a compressive residual stress and causing detrimental surface damage. Because of the relatively soft nature of AA7050‐T7451, shot peening can result in cracking of the constituent precipitate particles, creating an initial damage state. The aim of this paper is to understand the balance and fundamentals of these competing phenomena through a comparative study throughout the fatigue lifecycle of baseline versus shot‐peened AA7050‐T7451. Microstructure and surface topology characterization and comparison of the baseline and shot‐peened AA7050‐T7451 has been performed using scanning electron microscopy, electron backscatter diffraction, energy dispersive spectroscopy, and optical profilometry techniques. A residual stress analysis through interrupted fatigue of the baseline and shot‐peened AA7050‐T7451 was completed using a combination of X‐ray diffraction and nanoindentation. The fatigue life performance of the baseline versus shot‐peened material has been evaluated, including crack initiation and propagation. Subsurface particles crack upon shot peening but did not incubate into the matrix during fatigue loading, presumably due to the compressive residual stress field. In the baseline samples, the particles were initially intact, but upon fatigue loading, crack nucleation was observed in the particles, and these cracks incubated into the matrix. In damage tolerant analysis, an initial defect size is needed for lifetime assessment, which is often difficult to determine, leading to overly conservative evaluations. This work provides a critical assessment of the mechanism for shot peening enhancement for fatigue performance and quantifies how incubation of a short crack is inhibited from an initially cracked particle into the matrix within a residual stress field.     

Experimental Study on the Surface Property Changes of Aluminum Alloy and Stainless Steel after Impingement with Submerged Cavitation Jet

Strength of Materials - With the development of green manufacturing technology, high-pressure cavitation water jet cleaning and shot peening technologies are gradually replacing traditional...     

A Numerical Study Comparing The Effect on Residual Stresses of Two Different Types of Projectiles During Shot Peening

Shot peening is a widely used technique to improve fatigue life in metallic alloys. This processing technique introduces a subsurface compressive residual stress field through a plastic deformation of the surface caused by the impact of a large number of high-speed projectiles. There are a number of parameters that affect the residual stress field depth and magnitude. The effects of the impact angle, shot speed and shot geometry are currently being researched. In particular, substituting spherical cast shots by cylindrical cut wire shots is an attractive option, especially in terms of cost. The effect of shot geometry on residual stresses, however, needs to be further investigated. Because industrial-scale experimentation is costly and cumbersome, mathematical modeling offers a convenient alternative to carry out this type of research. The present work shows a comparison between the residual stresses generated by the impact of spherical and cylindrical projectiles on a steel substrate. This threedimensional model was developed using ABAQUS finite element commercial software (Release 6.12, Dassault Systémes, France). The results show that cylindrical shots generate residual stress fields that are higher in magnitude than those generated by a spherical shot. However, the residual stress field of cylindrical shots impacting the surface at an oblique angle shows an important degree of asymmetry. This effect is not found when spherical shots impact the surface at the same oblique angle.