Search Results (12)

Wear, fatigue, and corrosion are just a few of the issues that mechanical components in engineering experience, leading to surface deterioration. Enhancing the surface characteristics of engineering components is therefore essential. The surface properties of engineering objects can be improved by applying different surface treatments. One of these processes is shot peening (SP). Process parameters are crucial for SP. This necessitates the optimization of SP process parameters. In this study, we applied SP and vibratory shot peening (VSP) processes to different steel materials (AISI 8620, AISI 5140, AISI 4140, and AISI 1020) using different process parameters, aiming to determine the effects of these parameters on hardness, residual stress, and surface roughness. The highest compressive residual stress (CRS) and hardness values for shot-peened samples were obtained at the 24–26 A intensity for all steels. For all steel-group VSP samples, the highest CRS and hardness values were obtained at the 60 s −4 mm parameter. This paper aims to predict Almen intensity values using CRS, surface roughness, and hardness values from various steels. The supplied experimental data was utilized to estimate the SP Almen intensity value using a number of machine learning (ML) methods, eliminating the need for costly and time-consuming experimentation. With an RMSE of 0.0731, R2 of 0.9665, and MAE of 0.0613, the deep neural network (DNN) surpassed the other models in terms of prediction accuracy. The results indicate that artificial intelligence technology could be utilized to accurately evaluate Almen intensity. Full article

Shot peening is generally used to improve the fatigue performance of mechanical components. However, identifying the geometrical and mechanical characteristics of the shots that improve fatigue strength is still a challenging task, as there are many variables involved in the shot peening process. The present work addresses the effect of different shot media on the fatigue behaviour of an aluminium alloy 6082 T6. Four different shot types were used: silica microspheres, alumina shots, aluminium cut wire and zinc cut wire. Axial fatigue tests were carried out to obtain the Wöhler curves corresponding to each shot peening treatment. The surface properties of the shot-peened specimens, such as grain size, hardness, residual stress and roughness were measured to determine their effect on the fatigue results. The fatigue results revealed that silica and zinc shots increased significantly the fatigue life of the alloy, whereas alumina and aluminium shots reduced its fatigue strength. Almen intensities have shown to correlate well with grain refinement and strain hardening. However, better fatigue results were obtained with the shots that generated higher surface compressive residual stresses. It is believed that small and smooth shots are preferable to sharp and irregular ones, regardless of the Almen intensity or surface hardness attained with the latter. Full article

The study evaluated and compared the surface morphology, roughness, and coating structure of ultrasonic shot peening (USP)-treated samples of the NiCrAlYSi-coated GH4169 alloy used for turbine blades and discussed the influence of blade-surface roughness and coating thickness on aerodynamic performance. The NiCrAlYSi coating was deposited on the surface of the alloy using electron beam-physical vapor deposition (EB-PVD), and the NiCrAlYSi bond coat was subsequently surface treated at Almen intensities of 0.1 A, 0.15 A, and 0.2 A by USP. The results following USP treatment indicated that the bond coat becomes denser with a smoother surface and a porosity reduction ranging from 12.5% to 50%, accompanied by localized enrichment of Cr elements near the substrate. Additionally, the study examined the influence of coating thickness and roughness on turbine blade aerodynamic performance, validating the effectiveness of USP in reducing these factors, thereby potentially enhancing the aerodynamic efficiency of coated turbine blades. Full article

In this study, a combined discrete-finite element model based on the Almen intensity measurement test was proposed to evaluate the real shot peening residual stress. The discrete element analysis was utilized to simulate the random behavior of numerous shot balls, while the finite element analysis was employed to quantitatively predict the residual stress induced by shot peening. Moreover, the Almen intensity, an essential factor in the actual shot peening process, was taken into account. Initially, an Almen strip analysis model was established, and the multi-random impact analysis was performed to validate the good agreement between the analytical Almen curve and experimental Almen curve. Subsequently, the unit cell discrete-finite element analysis model was expanded for predicting the peening residual stress, incorporating the Almen intensity. The analysis results showed a significant correlation between the predicted peening residual stress and the XRD (X-ray diffraction) experimental residual stress. Therefore, it was confirmed that the proposed discrete-finite element random impact analysis model in this study could serve as an effective analytical technique capable of substituting for the actual shot peening process. Full article

In the present study, the experimental data of a shot-peened (TiB + TiC)/Ti–6Al–4V composite with two volume fractions of 5 and 8% for TiB + TiC reinforcements were used to develop a neural network based on the deep learning technique. In this regard, the distributions of hardness and residual stresses through the depth of the materials as the properties affected by shot peening (SP) treatment were modeled via the deep neural network. The values of the TiB + TiC content, Almen intensity, and depth from the surface were considered as the inputs, and the corresponding measured values of the residual stresses and hardness were regarded as the outputs. In addition, the surface coverage parameter was assumed to be constant in all samples, and only changes in the Almen intensity were considered as the SP process parameter. Using the presented deep neural network (DNN) model, the distributions of hardness and residual stress from the top surface to the core material were continuously evaluated for different combinations of input parameters, including the Almen intensity of the SP process and the volume fractions of the composite reinforcements. Full article

Micro-shot peening under two Almen intensities was performed to increase the fatigue endurance limit of anodized AA 7075 alloy in T6 condition. Compressive residual stress (CRS) and a nano-grained structure were present in the outermost as-peened layer. Microcracks in the anodized layer obviously abbreviated the fatigue strength/life of the substrate. The endurance limit of the anodized AA 7075 was lowered to less than 200 MPa. By contrast, micro-shot peening increased the endurance limit of the anodized AA 7075 to above that of the substrate (about 300 MPa). Without anodization, the fatigue strength of the high peened (HP) specimen fluctuated; this was the result of high surface roughness of the specimen, as compared to that of the low peened (LP) one. Pickling before anodizing was found to erode the outermost peened layer, which caused a decrease in the positive effect of peening. After anodization, the HP sample had a greater fatigue strength/endurance limit than that of the LP one. The fracture appearance of an anodized fatigued sample showed an observable ring of brittle fracture. Fatigue cracks present in the brittle coating propagated directly into the substrate, significantly damaging the fatigue performance of the anodized sample. The CRS and the nano-grained structure beneath the anodized layer accounted for a noticeable increase in resistance to fatigue failure of the anodized micro-shot peened specimen. Full article

The present study investigates the effect of shot peening (SP) on the mechanical properties and surface roughness of 7075 aluminum alloy during different stages and conditions of heat treatment. The mechanical properties were determined by measuring Vickers microhardness profiles and residual stress profiles, while the amount of alloying elements present in the solid solution of the samples under different heat treatment conditions was determined by measuring the electrical conductivity. The results show that the increase in microhardness near the SP surface and the maximum compressive residual stresses are mainly related to the content of alloying elements in the solid solution. Surface roughness increases with increasing SP Almen intensity, and samples with the highest microhardness and residual stresses have the lowest surface roughness. Full article

In existing simulations of the Almen intensity test, arc height is indirectly obtained by an equivalent method including a representative cell, a few shots and equivalent loading. Most of these equivalent methods cannot consider the transverse deformation of the strip, the complex stress state of the plastic hardening layer and process parameters, resulting in deviation from the actual test. This paper introduces an improved and experimentally validated discrete element model (DEM)-finite element model (FEM) to predict the actual Almen intensity. The improvement of this model is mainly reflected in the large and real number of shots involved in the actual Almen intensity test, shot–shot interactions, and real-size solid finite element model of the Almen strip. A new method for calculating the shot stream is proposed based on the test and considering test process parameters such as the mass flowrate, nozzle movement speed and nozzle–workpiece distance. The shot stream impacting the strip with a fully restrained underside was first simulated in improved DEM-FEM to bring the forming energy. As a second step, an implicit solver of the Almen strip FEM calculates the spring-back to simulate strip removal from the holder. The results achieved by the present approach are compared with the results obtained by the experimental results and those in the literature. The results show that the arc height and Almen intensity obtained by the present approach match much better with the literature than the traditional method. Some new results obtained by the improved coupling DEM-FEM method are presented. The influences of the transverse deformation and surface plastic layer on the deformation of the Almen strip are discussed. This improved method provides an alternative characterization method for precision peen forming simulation. Full article

The effectiveness of shot peening is mainly determined by the peening coverage. The peening coverage is required to be 100% for current technical standards of shot peening. With the increase of material strength, higher peening coverage is required in shot peening process. However, the influence of high peening coverage on Almen intensity and residual compressive stress is unclear, the difficulty mainly lies in the lack of quantitative description of peening coverage in finite element analysis. To analyze the influence of high peening coverage on Almen intensity and residual compressive stress, firstly an approximate quantitative description of peening coverage based on dent size, the distance of shots and shot numbers is proposed in this study. Based on this quantitative description of peening coverage, the arc height and residual stress of the Almen test are simulated with the finite element method. The simulation results of arc height and saturation curve agree well with that of the Almen test, by which the effectiveness of the quantitative description and FE simulation are proved. The further study indicates that in shot peening processes, the excessive peening coverage doesn’t improve Almen intensity and residual compressive stress. Full article

Vibropeening is a surface treatment process, which combines the peening effect of introducing residual stress with the polishing effect of reducing surface roughness in one single process step. Vibropeening equipment induces vibrations into the media to impart residual compressive stresses in sub-surface layers, as well as polishing on the surface of the work piece. In addition to process parameters, such as vibration frequency, amplitude, and media mass, which are well known in literature, this paper will focus on the study of two additional parameters: immersion depth and process time. It was found that the lower-middle section of the vibratory trough produced the highest Almen deflection. Different continuous treatment times were also studied to explore the maximum introducible residual compressive stress state, and it was concluded that an optimal time range is required to achieve the best residual stress profile. The study demonstrates that different process parameters can influence the effectiveness of the vibropeening process, and that these can be potentially optimized for higher treatment capability. Full article

This paper reports about the non-destructive evaluation of surfaces after severe shot peening via the Barkhausen noise technique. Residuals stresses and the corresponding Almen intensity, as well as microstructure alterations, are correlated with the Barkhausen noise signal and its extracted features. It was found that residual stresses as well as the Barkhausen noise exhibit a valuable anisotropy. For this reason, the relationship between the Barkhausen noise and stress state is more complicated. On the other hand, the near-the-surface layer exhibits a remarkable deformation induced softening, expressed in terms of the microhardness and the corresponding crystalline size. Such an effect explains the progressive increase of the Barkhausen noise emission along with the shot-peening time. Therefore, the Barkhausen noise can be considered as a promising technique capable of distinguishing between the variable regimes of severe shoot peening. Full article

Almen intensity and surface coverage are well-known to be the defining parameters of shot peening-based surface treatments. These parameters are directly affected by material properties, the extension of the contact zone, the geometry of the impact pair, as well as the impact rate and velocity. Such intricate relationships have resulted in often dissimilar predictions of shot peening effects even while using an identical combination of Almen intensity and surface coverage. With the fast pace introduction of new generation impact-based surface treatments, there is a need to find a more widespread parameter that would facilitate the direct comparison of all different treatments and relate the main process parameters to the resultant mechanical characteristics. Herein, we propose to use an energy-based parameter to describe the peening process in a more widespread approach, which collectively incorporates the effects of the Almen intensity and surface coverage, as well as the diameter, material, and velocity of the impact media. A set of finite element analyses was developed to demonstrate the correlation of the peening process effects with this energetic approach. Comparisons with the experimental data served as proof of concept, confirming that the proposed method could provide a quite good estimation of the effect of peening parameters on the treated material. Full article